Compact Cord Cover for hard floor

thingiverse

The goal of this project is to design a cover for an 8mm⌀ extension cord at my makerspace, strong enough to walk on, at minimum cost. The parts assemble to form a rigid triangle, with the top in compression and the base in tension.Filament usage: 170 g/m (52 g/ft)Filament cost at $20/kg PLA: $3.40/m ($1.04/ft)The STL files contain 100mm extrusions; you should scale them to the desired length.For example, to span a distance of 1080 mm, you could print the following:cord_cover_top_3x.stl, scaled to Z=180%, 3×2 copies: 180×3×2 = 1080 mmcord_cover_base.stl, scaled to Y=180%, 5 copies: 180×5 = 900 mmcord_cover_base.stl, scaled to Y=90%, 2 copies: 90×2 = 180 mmWhen assembling, stagger the top and base parts like bricks, with 50% overlap. The final base (would be #6 in this example) is split in half and positioned at the ends.The top_1x and top_3x STLs are equivalent, but top_3x is theoretically less wobbly because the 3 parts can support each other.I recommend printing 20mm extrusions first, for quality/strength testing:cord_cover_top_1x.stl, scaled to Z=20%cord_cover_base.stl, scaled to Y=20%PrusaSlicer settings for 'top':Scale in the Z direction0.2 mm layer height1 wall (wall+infill is stronger than all-walls)100% rectilinear infill0 top/bottom layers (let the infill handle it)3-layer raft with 0.15 mm Z distance (bed adhesion is important)Seam position: Random (print the horizontal stitches in both directions)No supportPrusaSlicer settings for 'base':Scale in the Y direction0.2 mm layer height2 walls100% rectilinear infill0 top/bottom layers (let the infill handle it)No raft (the base is a huge rectangle)No supportThe "8mm" STLs have 8.1mm⌀ of internal clearance. I haven't built STLs for other diameters, but they can be made in Fusion 360: Modify > Change Parameters > (wire_diameter, top_thick, extrusion_length)Longprint is loooooooooong.