CHAMP v1 - no support material!-

grabcad

Introducing my finalized CHAMP design for ISS, which requires zero support material. The large upper and lower parts can be pressed together, forming a strong bond. Be sure to attach the moving components before pressing as separation becomes difficult afterward. This design boasts a unique feature that ensures a robust clamp force and stable handrail connection through an oversized excenter clamp. When the handrail is secured, the large arms flex, tightening the grip. The CHAMP consists of four parts, taking around 8-9 hours to print with approximately 100 cm3 (6.1 in³) material usage. The upper and lower clamps must be printed solidly, or the standing rods will be too weak. Meanwhile, the excenter clamp can be printed with a low density (1.9mm raster) for optimal flexibility and bending. My model was printed on a Stratasys uPrint using the same resolution and layer height as the ISS printer. An alternative version without support material is available here: CHAMP v2. Considerations for improvements include incorporating honeycomb structures in specific sections to save material or increasing friction in the Z-direction by expanding clamping surfaces.