3030 Extrusion 180mm & coupler

prusaprinters

<p>3030 Extrusion and a coupler.&nbsp;<br>The goal is to find a way to print and replace aluminum extrusion in printer builds.&nbsp;<br>Why? Well, to do it all with printing. And the extrusion is cheaper this way.&nbsp;</p><p>Printed out real nice but joining these parts was a pain. Used anvil hammer to force the coupler into the v-slot.</p><p>&nbsp;!You might want to use hydraulic press since the fit is supertight and is hard to align while hammering. .!&nbsp;</p><p><br>Result was acceptable, but introduced a problem with the couplers underside where the bridging of slab on middle created uneven connection and bend the whole connection by some degrees.&nbsp;Possibly the slab on middle is useless and coupler is better without it…<br>Maybe someone can figure out and give me an advice how to go past this.&nbsp;<br>Overall the whole piece is very rigid, did not test the weight tolerance yet.<br><br>Coupler is printed with support. from build plate only.<br><br>All ABS, 100% infill or more perimeters. More fine surface you get, easier to apply coupler.</p><p>Also there might be some modeling flaws on the files provided since my 3d modeling skills are 3 months old.&nbsp;<br>&nbsp;</p><p>The coupler will snap in half quite fast when applied 75kg of weight on ends of extrusion while pressure point is on coupler ↓---↑---↓, wish I had way to measure this more scientific, but could apporiximate this coupled extrusion will snap under 10-15kg of horizonal force from coupler.</p><p>(added coupler with holes and place for hex nut to try how the part withstands horizonal forces with steel inside.)&nbsp;<br><br>Need to print new coupler to inspect results in opposite ↑---↓---↑</p><p>Need to print new extusion since I snapped the other half while trying to insert coupler with holes ( I guess inserted bolts cap thickend the part a bit, or my hammering was not aligned… )<br>&nbsp;</p><p>Also I will apply place for hex nuts to manually test how much the whole build takes load when twisted with torque wrench.<br>&nbsp;</p>