TS100 Soldering Iron replacement shell

thingiverse

A few weeks back my TS100's casing broke around the power jack, prompting me to design and print a replacement. After many iterations, this is what I came up with. As far as I can see, I am the first one to make it. I have released all of the Solidworks files so people can remix them (if you do, please mention me). This wasn't easy to design, so if you can, throw a coin my way. Features: - No support required - No hardware needed - A stronger design than the original - The tips are a press fit, eliminating strips screws - More of an "Industrial design," which makes the grip better (for me at least) What it lacks: - No protection window for the OLED display How to print: - You can choose any material; PLA works fine, but it doesn't have as much give, so it may break easier. ABS works better, but warping might affect some dimensions. - Print the parts exactly how they are laid with a 0.2mm layer height - The cap has a built-in 0.2mm support inspired by Maker's Muse on YouTube - Use three perimeters and 100% infill for the shell; the cap can be 20% EXTRA TIP: I don't have a heated bed, so I used a three-layer raft on tape with PVA glue and two halogen 50W 12V light bulbs from Pound Land to print in ABS. You just need to position them at the ends of the parts that are furthest apart, so the lights warm them up while the extruder prints on the opposite side. The prints turned out good, but it's really sketchy and I wouldn't recommend it; I'll leave a picture below. I had to wear sunglasses while working and still got dry eyes. EDIT: Printed a version in green el cheapo PLA, and it looks and feels so much better than the ABS.