Geared light switch

grabcad

This is a design for an elaborate steampunk-themed mechanism for flipping a light switch on and off. It's intended to be fun to use, incorporates a gear train and a rack-and-pinion system, and measures approximately 91mm long, 103mm wide, and 72mm tall. The design can be easily printed using FDM technology, as shown in an image on the gallery detailing how each piece would print. I simulated printing each part, and they all printed with ease, requiring minor supports for just three of the eight different parts. Assuming the parts are oriented correctly, the entire model would use 49 grams of filament at a 13% infill rate; however, any infill level is acceptable. When you pull the handle, a 20-tooth gear drives a 15-tooth gear, which in turn moves the rack up and down on both sides. The two racks are connected to a block that moves with them, flipping the switch into the opposite position. Pulling downwards will turn the switch on, while pulling upwards will turn it off. The gears are connected to axles, which rotate within support structures situated on each side. These support structures can be secured to the switch cover plate using an adhesive. The support structures also feature extensions that fit below the rack, keeping it in place. I have added semi-spheres with holes at their centers, which can be placed on the axles and act as mechanical stoppers to prevent excessive movement of the parts. I have taken into account tolerances when designing these stoppers; however, they may vary slightly depending on the printer used, and parts can be scaled accordingly.