Heavy Duty 2040/4040 Extrusion Bracket

prusaprinters

AboutI had a heavy kitchen tabletop I wanted to salvage as a printer table. I used dual-slot 4040 extrusions but the brackets were not strong enough. This is the solution.These joining brackets are ~240mm long. They must be printed in ABS or another suitably rigid and strong plastic.Bill of MaterialsPrinter enclosure that is stable above 40C150g+ of ABS8x M5 x 16mm socket head cap screws8x M5 lock washers8x M5 tee nutsPrinting InstructionsRotate the model 45 degrees if you are printing on a 220x220 build plate.Material: ABS/ASAEnclosure temp: 45C with unmodified ABSWalls: 2mmInfill: 30% or higherAdhesion: brim and adhesiveLayer height: 65-75% of nozzle diameter** This is 0.25ish to 0.32ish for an 0.4mm nozzle. Thicker layers improve strength.Installation TipsLock washers are not strictly necessary, but strongly recommendedUse roll-in tee nuts instead of drop in.If you have any warp in your print near the edges, the screw holes closest to the warping will be unusable. This is okay if you still have 3 usable screw holes per side.Carefully check the angle and flushness of the bracket during installation.