Aluminium T-Slot Extrusion - 8020 derivatives - 1-8 Slots

thingiverse

As part of a DIY project, I set out to build a modular robot from scratch using spare parts. To allow for adjustments, I decided to use T-slot 8020-style profile as my base. Two immediate issues arose: First, I needed more slots than standard 8020 extrusions provided. Second, purchasing actual aluminum extrusions was too expensive. Luckily, I had Fusion 360 and a 3D Printer at my disposal. Throughout the design process, I repeatedly revised how many extrusion slots I would need for this project and future projects alike. To reflect this, I created multiple designs with varying slot counts (1-8) which are included here. Next, I struggled to determine the best print orientation. With a Prusa Mk2.5 at my disposal, I opted to align the long axis of the extrusion with the x-axis, requiring the extrusion to lie flat on the bed. This necessitated support for overhangs. To minimize cleanup, I used a sacrificial bridging layer instead of relying on extensive support material removal. You can choose to print this lying flat or standing upright; I've included two versions for each slot size: one with and one without the sacrificial layer. I designed this profile with a 25cm length as it suited my needs, but if your printer's maximum dimensions are too limited, consider non-uniform scaling in the long direction to meet your requirements. Due to the central hole, multiple pieces can be connected end to end securely if needed.