Makeshift Light Duty Non-polarized 2-Pin AC Plug NEMA 1-15 IEC Type A

thingiverse

Use at own risk, do not make this unless you had electrical safety training. One of those nights, when you need few AC plugs to get project moving, do not have spare extension cord to cut it from and HomeDepot is closed. So you rig up some. Only had some thin gauge of galvanized sheet from some spare duct piece, so I triple folded. It was easy to solder on. Result is 1.35mm thick, specs call for 1.4mm so close enough, fits nicely and needs about similar force to pull out as factory made plug. Assemble it by putting heatshrink on, remove top insulation, push individual wires through plug body, solder blades on, then pushing blades in and apply bit of hot glue from both sides. Push heat-shrink inside while glue is still liquid and then shrink it. It is quite tight fit, had to use pliers and good amount of force to push blades in. Dielectrically, 3d printed PLA is almost as strong as PVC, about 25kV/mm. Blades/prongs should be 18mm out and give at least another 5mm in. SCAD file is parametric, so adjust to your situation.