Rhino Vortex Roofrack Lightbar Mount

thingiverse

So this is my first dive into simulations on objects. By running these simulations, I've discovered that a lightbar traveling at 100kmh will generate roughly 150kg of wind drag or 1,500 newtons - I rounded it to 10 for every 1kg = 10N, which seems closer to the actual value of 9.8. Through all my simulations, buckling occurs at points where mounting bolts sit and the lightbar begins to bow outwards. Adding a washer increases the strength on the outside while the lightbar frame itself strengthens the inside. All simulations were done under the assumption that the object is printed in ABS plastic. Other plastics will produce different results, such as PETG which I prefer and isn't accounted for in the simulation software. This design is meant to fit into the top track of a Rhino Vortex Roof Rack. I have no affiliation with Rhino Rack or their products, and this isn't an approved product by them - it was just done for fun. Drawing inspiration from Rhino, this object is non-commercial and non-derivative. If necessary, feel free to modify it extensively to fit your specific lightbar needs, but please don't create derivatives that pop up on Thingiverse. Once again, I'll stress that this was designed purely for fun to see the limitations and advantages of Fusion 360. I will be printing this myself and attaching my own lightbar to it, but I take no responsibility for anyone else's potentially damaged or lost lightbars - I simply can't provide advice based on the vast array of available lightbars, printers, settings, and plastics. USE THIS AT YOUR OWN RISK!!! Feel free to post your makes if you create this. I'll be printing mine in PETG at 0.05mm layer heights and 265 degrees once it's done, and I'll update with my results. I might go as high as 0.1mm or as low as 0.01mm - who knows. For best results, print the largest faces flat against the print bed, which was taken into account in the design. It's also a good idea to randomize the Z-Seam to avoid introducing weak points in the model's Z seam. Based on my personal experience, the best approach for objects like this is a high amount of 3D Honeycomb infill - but the structural tests assume a solid model, so keep that in mind. The software can't account for 3D printing. If you want to see a video of the stress test, check out https://youtu.be/EMQxSytt6BI on YouTube.