Sleep Number Bed Leg

thingiverse

Got one of those fancy Sleep Number beds but the leg broke? You're in luck! I was asked over the holidays if I could print a bed leg to replace one that had snapped. They sent me the leg to turn into an STL and to print. I didn't make the copy exact with the taper on the lower part of the leg because my goal was to create something strong enough, with aesthetics taking a back seat. The design matches the original with some reinforcing added on the back. There are three designs uploaded - one regular solid file and two hollow ones with different wall thicknesses. The solid one should be printed with 50% or higher infill, but that might use almost an entire spool of material. To keep material use limited, the hollow files are designed to be filled with canned expanding foam. There are holes in the top and bottom of the part to allow for the foam to be sprayed inside. Supports will be needed on the outside overhangs, but not inside, as internal supports would interfere with the foam and make the part weaker. I figured it wouldn't hurt to share the design here. I've saved myself many hours of CAD work by simply searching for something here - it's a great resource! UPDATE: I received feedback that the current design should fit very well indeed. The expanding foam technique worked great, completely changing the part from squishy to rock-solid like cement. Be sure to let the foam solidify for about a week before using the bed leg.