Creating a 3D printed spare part

Printing out already created models downloaded from sites like Thingiverse is great, but what to do you do when you cannot find the part you need/want there?

In my case I needed a new shower handle holder. Because of a leak in the hose, it was replaced. But the new hose had a hexagonal screw at the end, so it didn’t fit into the original round holder:/

Original round shower holder
Original round shower holder

Modeling the first draft

I created the model using Autodesk Inventor. The job could of course have been done in many other softwares, such as Google Sketchup.

First i measured the critical dimensions on the original part. By critical I mean the dimensions that has to be correct to make the new part fit into the existing structure.

Some of the original parts
Some of the original parts
Measuring original part
Measuring original part
Measuring
Measuring

Then I began modelling the new part. The only thing I was going to change was the hole: It need to accommodate the new hexagonal hose end.

Inventor screenshot
Inventor screenshot
Creating the hexagonal hole
Creating the hexagonal hole
Finished draft
Finished draft

This first model was designed with zero clearance, and with these goals in mind:

  • To find out what clearance is necessary to use so the part fits the rest of the structure.
  • To find the weakest structural point. (Simulation could work, but naaah, not so fun:P).

Printing and testing the draft

The first draft was printed with an infill of 20%.

Printing the first test with 20% infil
Printing the first test with 20% infil

Then it was time to do some structural tests:)

Broken test piece
Broken test piece

With only 20% infill, the structure is not that solid, so it was easy to find the weakest point. I did also identify were I needed to adjust the model regarding the clearance.

Modifying, printing and assembling the final part

Time to modify the draft! Instead of adding fancy support structures, I just made things thicker. Engineering at its finest!

Rev. B: Mr. Robust!
Rev. B: Mr. Robust!

First, I printed this with only 20% infill, because it’s faster.. It did fit, so the part was printed again, this time with 100% infill (it took 2,5 hours).

Exploded with printed part
Exploded with printed part
Testing thr most critical dimensions
Testing thr most critical dimensions
Finished and installed
Finished and installed

I am now a happy owner of a custom made shower handle holder. Yay!

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