Folger Tech Kossel Top Vertex Aluminum 2020 Caps

thingiverse

I redesigned the top caps to cover up those sharp corners, which were protruding from the top of my design. I made sure they fit perfectly by adding an extra 1mm to the verticals' height of 2020's, so I increased the cut on the inside to 21mm. This way, there are no problems printing above the cut. You can adjust the height of the inside cut if your verticals are a different height from the vertex by changing the variable Alum_Ht = 21; to the height you need in the openscad file. The aluminum vertex parts have a convenient hole on each side that makes it easy to use a screw to hold the top cap in place with a base plate at the bottom of the top vertex. Print one VertexTopCap_Rev5.stl & VertexTopBasePlate_Rev5.stl for each vertex, and use 2x M3x30mm screws with locknuts for each cap. There is also a VertexTopBasePlate_3x_Rev5.stl file if you want to print all three base plates at once. To get the verticals exactly 20mm above the vertex, I used a 40mm plastic spacer jig (Top40mmJigSpacer.stl) to set the top of the endstops before putting on the top aluminum vertex parts. That way, when I put the top on the verticals, they were all within a 1/2mm of 20mm above the top. I included a photo of how I did that. An openscad file is included for the Top caps & the spacer jig. The Top Cap & Base Plate are created from the same openscad file. On the base plate, there's not much plastic holding the two sides together, but that was what matched the aluminum vertex profile & they're really only needed to hold the bolts in place from the top. I printed these with 30% honeycomb infill to get a better honeycomb looking pattern for visual appeal. You should be able to print these at 20% or less fill.