KeyConnect RJ45 Jack

prusaprinters

In my IT work, I sometimes need to install single RJ45 jacks in odd locations. Wiring standards dictate that wires run into a wall jack or patch panel, but you don't often have the correct plastic jack on hand when you need it. I've used (what maybe a North American standard from Belden) RevConnect jacks that fit into any KeyConnect standard opening. I've attempted to duplicate that KeyConnect standard  so  I can create a single jack which can be wall mounted when I need to run one or two cables to a location that won't accept wall plates. This is a work in progress and I've had many failures. First, I've discovered the beauty of PETG. This part prints well in PLA but is a little too stiff. PETG is strong and more pliable. I strongly recommend PETG. There are two problem areas in this print, that I've shown in one picture and these are the 2 “bars” that hold the clips of the RJ45 connector. These bars must be somewhat precise, but they are bridges and so printing them accurately can be difficult to those of us with little experience in bridging. I could print in two pieces and glue, but I'm still exhausting the single print options.I print the part @ 0.2mm Quality, 3 perimeters, and I've  printed with and without supports. I print the part with the RJ45 opening on the print bed and screw tab in the air. I've had more success using supports (with PolyLite PETG and PrusaSlicer on an MK3S+). Recently, I tried Prusa Black PETG and it worked well without supports: I put the fan always on @80% and reduced the non-first layer temps to:  230/85. The fan is to improve the bridging. Last 2 prints did very well.When printing with supports, I simply turn on supports and clean them out later. Sometimes, the edge of these bars fuse a bit with the support material and you get various amounts of quality in the edge that holds the clip.I build and test about 4 at a time and keep them in my toolkit. If you print and try, let me know how you make out and I can adjust the model. The top flat plate can be used to put a label as shown in the pictures. The STL model has no label, but you can add at slicing time. The orange models were early versions. The black is the latest model.