A set of connectors for making boxes out of 20 mm square aluminium profiles

thingiverse

This is a collection of 3D-printable connectors used for making heavy-duty boxes from 20 mm square aluminum profiles. The images display how I used them, yet they're universal for any box size; just trim the aluminum profiles to the desired length. These connectors cover all sorts of configurations - ones for simple boxes, intermediate brackets, mounts for 3D-printed wheels, and mounts for trolley-type extendable handles. Instructions: For regular corners, use corner.stl. Eight pieces of these will build a basic box. To add support beams or dividers, print intermediate.stl. You can also employ it as bracing, though its main utility lies in creating internal partitions that need to be rotated for optimal fit. To construct boxes with wheels, download and print the wheel-studded left and right pieces along with Emmet's bearing design: http://www.thingiverse.com/thing:53451, consult image 2 for reference. If you wish to attach a trolley handle to your box, print the left and right corner +trolley stl file to substitute normal corners, then two more handle_corner.stl files to serve as the extendable trolley handle. Refer to picture three. When mounting this, screw both end parts securely together with a self-tapping screw on both ends. This way your box's extendable portion remains in place and stable. Print Settings: Printer: Craftbot Rafts: No Supports: Yes Resolution: 250 um Infill: 25-33% Notes: Print any number of necessary components (14 are used in the displayed example – four corner connectors, four intermediary pieces, two corners with wheels mounted, and two connector handle_corner parts). Since they fit tightly, double-check the rods' exact dimensions if unsure (a discrepancy might result due to a bigger non-anodized piece that causes fitting problems). To achieve an optimal output, I suggest printing in PLA; its sufficient strength also helps when choosing other print mediums. On the flipside, though ABS offers improved performance over time through the increased durability gained from proper chemical reaction with a certain environment's high humidity levels resulting to enhanced strength, issues may appear due to slight dimensional variation. If necessary scale your build +5%. If your target part falls under "structural support," ensure using the optimal settings (a more aggressive melt zone ensures adequate bonding between successive printing layers): Use hotend temperatures a few degrees higher than normal - use 10 for PLA and an extra 20 Celsius degrees higher than you normally print with to gain stronger bond. After printing your parts, start building the structures by aligning your desired materials – these may range from cutting your desired length aluminum rod pairs into appropriate halves before slipping it securely into their matching printed holders or securing using screwheads for easily removability of parts that form a construction block system