Scooter Ignition Cap - Kymco (2004)

thingiverse

I picked up a used 2004 Kymco Agility 125 scooter last summer, and after just one month, the ignition cap came loose due to a broken tab. This turned out to be an excellent opportunity to tackle a real-world problem using 3D printing technology. The process was surprisingly straightforward: I needed to create three prototypes before getting the measurements spot on. Although it's unlikely that many people will print this item in the future, at least one person will eventually have access to a functional part when their own breaks. If you happen to print one for your scooter, please reach out and let me know. Print Settings: Printer Brand: Printer: Deltaprintr Kit Rafts: No Supports: No Resolution: 0.4mm Infill: 30% Notes: This model produced several successful prints without supports. I used Hatchbox Blue filament for the job. If the print doesn't fit snugly on your scooter's ignition shaft, try filing down high areas or scaling it down slightly to get a better fit. How I Designed This: I was working at the Foundry Makerspace and wanted to create an example of a real-world 3D printing challenge for students in the Robotics Club. To help them grasp the design process, I brought in the original cap and used calipers to measure every nook and cranny. I then modeled the part using Sketchup Make, highlighting key steps along the way. Instead of using standard 3D text, I decided to go high-tech by incorporating icons for the lock and power positions. When I finished modeling, I exported it as an STL file. A colleague had recently purchased a Delta Printr Go 3D printer, and I had told him about it during my NYC World Maker Faire trip on October 1-2, 2016. It took a couple of prototypes to get the part just right due to slight variations in printed material. After the third try, the part fit perfectly, and I was impressed that the icon appeared on the print as well.