Sleep Number bed leg fit to MK3

prusaprinters

I wanted to print a replacement leg for a SleepNumber bed. I found this excellent model, https://www.thingiverse.com/thing:3339457 but it does not fit the MK3 build volume. Using nothing but PlusaSlicer and a little trial and error I managed to cut the leg into two parts, add a joining peg for support, and print the whole design in one go. The high level process was: Load the partCreate ‘peg’ holesModify the part → Add negative volume → cylinderAdjust the size of the peg holes appropriate to your needs. I wanted a strong peg so I made them about ⅓ the size of the leg. Optional: Unlock the object dimensions and make the cylinder oblong to enable the parts to be locked into a given orientation. This was not required for this example. Be sure to note your dimensions, you will need them later. For this project they were 30x45x50.Move the modifier to the correct spot. This may take some trial and error. For this project I made the modifier have the same X and Y coordinates as the leg and changed the Z to move the ‘peg’ higher into the model where the cut would be.Perform a cut on the model where the middle of the peg is. Use ‘keep upper’, keep lower', and ‘rotate lower part’ options.See if the cut and peg seem like good locations. Adjust the negative volume and cut locations as needed until you have what you need. Add a shape → Cylinder and use your dimensions from above. I cut 1mm off the height to allow for fit and glue.Slice for strength and print. I used 6 perimeters, 20% infill, and printed in PLA+. I think it was overkill. Notes:The peg is 1mm shorter than the holes to allow for glue if you wantMy printer is pretty well dialed in on dimensional accuracy (prints are almost exactly the right size) and the fit of the parts is excellent. So much so, I probably didn't need glue. If you have a hard time with the fit, print the plug slightly smaller and glue it in place. If you are worried about strength, you may want to modify the peg to print sideways for added strength. To do this I would just shave one side down flat, you don't need to have a completely filled peg pace IMO.