Brio - Mechanical (Geared) Interchange/Switch - M1 Track

prusaprinters

<h4>Overview</h4><p>I had downloaded and printed some of the switches for brio as my son has several powered trains that need a guide. &nbsp;The issue with those is that the stick that comes out of the side blocks cars or ships on his playset and there was a desire to make things more compact.</p><p>Also, this is been designed to be remixed into a signalled interchange as additional add-ons to this print as described in future iterations below.</p><p>I printed these switches with Amolen wood PLA for the track and Prima select red PETG for the functional accessories. &nbsp;The optional sign was printed in grey Prusament PLA. &nbsp;<br><br>All the components can be printed in PLA but I have found that the accessories are more durable if printed in PETG.</p><h4>Assembly Notes</h4><p>You will need to decide if you want a right or left turn. &nbsp;As the mechanics are under the track, it is not possible to flip this over to reverse directions. &nbsp;<br><br>You will want to print one of each of the common accessories and then one of each for the accessories that are paired to the track (RH or LH)<br><br>There are a couple of pieces with tight tolerances, to ensure that things do not move once assembled. &nbsp;These are:<br><br>1. Retaining plate: &nbsp;After you insert the 50mm gear, the retaining plate goes over this and slots into the holes on either side. &nbsp;This will be a tight fit by design. &nbsp;I have found success in positioning the peg into the hole and them pushing down firmly on a flat surface on each side to seat. &nbsp;This plate keeps the 50mm cog within the assembly. &nbsp;It should be flush to the bottom once assembled.<br><br>2. 20mm Gear and Gear Cap: &nbsp;The gear cap shaft is intentionally .5mm wider than the gear hole. &nbsp;This is to ensure a tight fit with no slippage. &nbsp;One side of the gear is filleted and that is the side that needs to face into the track. &nbsp;That should help push the shaft into the gear. &nbsp;Similar to the retaining plate you may find success if you position the gear and cap and then pushing down the track on a flat surface.<br><br>In general I found forcing things too much causes breakages. &nbsp;A tip I found useful was to lubricate parts with liquid soap to help put in place if there was issues. &nbsp;Apologies if you have assembly issues, printing screws or fasteners at these tolerances does not seem like the right answer.<br>&nbsp;</p><h4>Future Iterations</h4><p>I had started to modify this design to become an L1 track (Male peg at the single track and female holes at the switches) but I found that cutting the holes would interfere with the gearing. &nbsp;I note that Brio themselves on their switching station do not offer an L1 option so I don't think this will happen for a while. &nbsp;It would require some major tinkering with the gearing and potentially more complex movements. &nbsp;<br><br>If you are ambitious, there are a set of <a href="https://www.prusaprinters.org/prints/61485-brio-m1-signal-lights">Signal Lights</a> that can be printed to provide overhead signals for the track. &nbsp;They work well but for smaller children they may not survive the rigours of play<br><br><a href="https://www.prusaprinters.org/prints/61485-brio-m1-signal-lights">https://www.prusaprinters.org/prints/61485-brio-m1-signal-lights</a><br><br>Alternately, there is an add on of <a href="https://www.prusaprinters.org/prints/63126-brio-mechanical-switch-signals">dwarf signals</a> that are more sturdy and simpler both in mechanism as well as surviving daily play. &nbsp;These can be found here:<br><br><a href="https://www.prusaprinters.org/prints/63126-brio-mechanical-switch-signals">https://www.prusaprinters.org/prints/63126-brio-mechanical-switch-signals</a></p>