3D Printed Hinge with Electrical Leads

grabcad

In this project, I opted for a challenging task of integrating electrical leads into a traditional hinge created via 3D printing. Initially, I considered including a conductive layer on the mating surfaces; however, concerns about intermittent connections and wear prompted me to reconsider. Consequently, I decided to coil the "wires" (red and green) around the hinge pin, utilizing the coils as strain reliefs and service loops. Additionally, leaving the wire paths hollow offers potential for fluid conduction. Given that flexible, conductive polymers for 3D printing are still in development, an alternative approach would be to keep the wire paths empty and inject conductive paste post-printing.