Clamp with threaded bolt.

grabcad

The clamp necessitates tension adjustment to prevent slipping on hand rails; however, a regular plastic clamp loses tension over time, especially with repetitive use. To counter this issue, a threaded connector is used to provide tolerance compensating tension. After the initial prototype, design improvements were made, including printing the threaded bolt horizontally for maximum strength utilization. The final version uses 28g of material with 100% infill and requires no support during printing. Testing was done on an Ultimaker 2 using PLA due to availability, and the thread operates effectively. The horizontal design also features two flat surfaces for increased durability. Weight reduction holes were added based on assumed load paths, but FEA analysis was not performed. Parts include a clamp (bracket_v3_p1) and bolt (bracket_v3_p6). Note that the Catia files might have lost structure during use. Many thanks to Mark Fuller for his input regarding the bolt design.