Physical button old machinist style

thingiverse

This is a real physical switch button with feedback. Derived from an old industrial grade momentary push button switch assembly. Real switch feeling provided by heavy spring-loaded actuator and the click of the switch at the end of travel. Please take note, even if engaging a latching switch, the spring-loaded push button will return to start position when unpressed. This thing is not easy to adjust and assemble. No, it's not just printing out parts and putting them together. When choosing the switch: The required travel on its pusher must be no longer than 5.5mm (limited by maximum travel of push button, stay safe with 4.5mm). If you want it easy, don't start making. If you still want to make this power switch thing, it could be changed in that way: - Remove the spring from the button cap. - Modify the pusher in designer CAD, make it longer, give the shaft an opening according to shape of power switch pusher. For clarification: look at caps they can be had with; they did just that. Then you have a permanently connected button cup. Some pics are showing earlier made parts. Just to give you idea. Latest pic shows monstrosity of mains power switch assembly with the additionally supporting shim/ring. The seen screws are too long, but I had nothing else by hand. Should I have made something with thread and nut instead? Perhaps. Always do a dry run before putting it into final position. Check if it triggers the switch properly. Now several configurations available. Choose from momentary or latching push button using 8.5mm switches up to mains power switch. Printing out is no hurdle. But knowing dimensions of switch you have (size/travel) and making a fit with dimensions defined by switch body and pusher with its travel (start and end position) can be challenging. All parts printed are made using PETG. Take PETG or ABS or something that doesn't break easily. Huge benefit, it forgives when applying much force on threads. PLA might break easily. Anytime recommended, predrill holes. Use a fine file as reamer. The initial configuration the switch body holds a small 8.5mmx8.5mm switch (momentary or latching) inside. The mount mechanics allow mounting on plates from almost zero up to 22mm thickness. See pics. For the small 8.5mm switch, they do exist in many configurations with different length of pusher, with or without caps. There is plenty of room to adapt it to needed spacing (distance bottom of button pusher relatively with top of small switch). Some tinkering needed sometimes. Newest configuration: The most tricky to adjust and assemble configuration. Have attached the real mains power switch. No LEDs with this configuration planned. In my case, screws holes on switch metal bracket had to be drilled up to 3.5mm. Assembling this configuration is not that hard on desk but it will when you are going to put everything together from inside of existing tight case. Mounting from inside against the inner side of front plate might pull your hairs. You have been warned. Some files: -Mount cap with mount screws for mains power switch i.e Rong Feng SS-160 -Width 18mm or smaller, -Holes distance 20mm -Pusher top to mount bracket top surface 18.8mm, if too long cut it the needed length -Washer 12mm -Template making a shim for mounting against sensitive/brittle frontplates -New cap covering pcb. -New cap covering pcb with lugs for mount screws. -Preproduction file released, combines formerly separated pusher skirt and switch holder into one part. Parts used: -Mini switches like "Push Button Switch ON/OFF DPDT 6Pin DIP 0.5A 30V DC 8.5x8.5mm" -Steel made spring, diameter 16-16.5mm 25mm length -Plastic screws 3x12-16mm, screw head no more than 2.5mm tall -Washer, diameter 12mm, thickness 1mm, hole size ca 3mm -2*LED 5mm -Mount screws: 2x M3 20mm with nuts