2020/2040 Linear Rail Mount Helper (Customizable)

thingiverse

I am currently working on designing my own 3D printer based on standard 2020 beams. A common challenge that arises when mounting linear rails is getting them perfectly centered, as the hammer nuts or pre-mount nuts often have a slight play that can add up quickly. This issue becomes even more significant when dealing with two parallel rails, where misalignment could cause the x-axis to shift depending on the y-axis position. There are probably alternative methods for making the mounting process easier, but I opted to use my 3D printer to create this simple tool instead. Here it is. Please note that this design is not a new way to mount linear rails; rather, it serves as a helper to ensure perfect alignment before mounting. When printing top-down, no support is needed, and with a 0.2mm layer height, the print time comes out to around 20 minutes, depending on your printer's speed and settings. I used a brim, but it's probably not required for small, quick prints like this. However, the look doesn't matter, and the top face is not essential, so you can leave the brim on and keep it as is. Make sure your printer is properly calibrated before printing, or the part may snap or be loose. Depending on the rail's length, you might want to print two of these helpers - see below for more information. This design defaults to MGN12H linear rails on a 2020 beam, but I've included a spreadsheet with all measurements, so you can easily adjust the model to fit any rail and beam dimension you need. I created this tool because I needed it myself, and maybe it'll be useful for someone else out there. To use this helper, simply place the rail onto your beam and clip the model over it. Press down on it until the lower section encloses the 2020 beam on both sides. When printed with a calibrated printer, it should fit perfectly and prevent any sideways movement. Place your nuts and screws into the rail without applying too much tension - using at least four screws is recommended, but feel free to use all of them if you prefer. Slide the rail over the beam, inserting the nuts from the side. Once everything is in place, it's time for the helper. For longer beams, consider clipping one helper to each end of the rail instead of just having one in the middle. Once done, the rail should be perfectly fixated dead center. Simply tighten all screws, remove the helpers, and your rail is mounted perfectly. I think this process can't get any easier than this. Update: I've added a 40mm version for use with 2040 or 4040 extrusions on October 10, 2019. Happy Printing!