Cup Holder Insert

prusaprinters

Tired of not fitting your coffee mug in that fancy cup holder in your TV or movie couch? This model will fit into any existing cup holder, and provides an easy way to keep your coffee or evening tea stable while enjoying a movie.Updates2022-12-28: A Fusion 360 file has been added, as well as some .step files.2022-12-28: I removed all the old designs, since I don't think they are useful. I cleaned up the documentation as well.Printer SettingsThe example gcode was done for speed, and using a 0.6mm nozzle. You should not need support for any of these files. Layer height can be 0.20mm or whatever you prefer, the example uses 0.36mm layer height for the bottom portion, and switches to 0.20mm when the rounded top pieces are starting (around 68mm layer).Infill does not need to be high, I printed at 10% infill using Adaptive Cubic (my favorite). For extra strength, instead add an extra peripheral if needed (I used 1.2mm peripheral).Updated modelsI've removed the old models, and now only support the new versions, which have taller, notched walls for the handle of a cup. The design comes in four versions:Solid (probably best for FDM printing)HollowHollow with a hole (probably the best for resin printing)Threaded (which lets you adjust the height accordingly), in 3 sizes.The hollow versions should work for any printer, without supports, including resin printers. All models have a base diameter of 90mm, and a cup depth of 60mm. Use these when calculating the scaling you have to do to fit your chairs.Scaling the modelMeasure the diameter of the existing cup holder (the inside diameter), pad at least a few mm's.Measure the depth of the existing cup holder, and again pad a few mm'sCalculate the scale against the provide dimensions, and when printing, scale accordingly.Example scalingMy couch had a 80mm diameter cup holder, with a 66mm depth (both padded)Scale X: 84/90 == 93%Scale Y: 93% (same as X, since it's a circle)Scale Z: 66/60 == 110%Remember to pad your measurements properly, you don't want a super snug fit here, or it will never come out of the cup holder. I'd pad at least 2-3mm in each direction.Threaded modelsFrom suggestions and discussions on the forums here, I've added a threaded version, well 3 of them, which makes it easier to adjust the depth without changing the scale. This prints in two parts, “top” and “bottom”. There are three variations, 80mm, 85mm and 90mm diameter, and probably can be scaled somewhat.Top part should likely be printed with at least some supports in the hollow area, the bridging will be severe otherwise. This is all hidden, so doesn't have to look perfect.The bottom part should be printed without supports, and these are the same for both the original and the “2021” models.The threads should be a good fit, I tried several prints to get them tight, but not too tight. If anyone experiences probleFeedback welcome!I think the 90mm diameter is generally good, but I'm contemplating making either a second set of cups with a 65mm cup depth. Or, make 65mm the default; I've so far done 3 different cup insets, measuring from 63mm to 66mm, so 65mm may be the better default on the depth.