Corner Bracket 20x20 - (was) Untested - Now tested.

thingiverse

The idea is to utilize extruded square aluminum as a structural framework. The internal dimension measures exactly 20.5 millimeters. Initially, I found 20 millimeters to be somewhat too tight. The screw holes are 5 millimeters in diameter, but unfortunately, not all of them can be utilized due to their alignment on the same line. Nevertheless, if this is indeed the desired outcome, it's perfectly acceptable. I took a close look at the corner and made some adjustments to ensure a seamless pattern. This approach not only eliminates any potential cracks that might have developed in my previous attempt but also allows me to rotate the print around the trimmed corner for optimal consistency. I would greatly appreciate any suggestions you may have regarding this matter. The file in question is Corner_Bracket_3_cornerholes.stl, and I was quite dissatisfied with the degree of movement I experienced with the initial bracket design. To address this issue, I tweaked the fit to make it slightly more precise while still allowing for easy tube insertion. The dimensions have been adjusted to precisely 20 millimeters. As of today, I can confidently say that this revised design has been thoroughly tested. One of the primary challenges when working with 3D printing is achieving accurate results. Although we possess infinite precision in CAD software, the molten plastic inevitably undergoes shrinkage and deformation upon cooling, resulting in an accuracy of around 100 microns. To overcome this issue, I recommend submerging the bracket in hot water if it doesn't fit perfectly due to slight shrinkage. According to online sources, the material starts to become saggy at temperatures above 60°C, but when attempting to force it onto a metal surface, boiling water may be necessary. As a compromise, simply use warm to 3/4 boiling water to achieve the desired fit.