Mar 6, 2012
admin

3D printing to the rescue

I bought a new bicycle, recently. My first with drop-bars. The additional brake-levers ease my mind, but make it more difficult to attach any more stuff. So I went looking for a well-reviewd, certified (German Straßenverkehrszulassung) headlight with a clamp that would fit into the space right next to the stem.

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The Busch & Müller Ixon Pure seemed to fit the bill. It comes with a too small clamp, but a larger one can be bought separately. Only after doing so, I realized the the lamp is put on in the opposite direction for this oversize clamp! This means the business end has to be in front of the bar, where I do not have enough space thanks to the cable connection-thingys of the brake levers.

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What a great opportunity to see how far the Free Software parametric solid modeling application FreeCAD has come! The 0.12 release didn’t cut it, but with a checkout a while later, I managed to model what I call the sled, with the relevant part put on in reverse. There were a few issues I had to work around, but except for some fillets I had to do without, I suceeded. Not production ready (not that anoyne claimed that), but very promising. Kudos to the developers!

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After having a quick look at the mesh in Blender, I went to shapeways.com. They claim their strong & flexible material can be used for living hinges and springs, and as far as it is required in my case, it works fine.

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The quality of the surface and the corners is not great, but aside of the those ridges on the lever, overall precision seems to be excellent, as far as I can tell with such a small part. It fits very tightly, but so does the original.

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The original sled has a metal inlet for the screw thread. I simply modeled a tunnel with the smaller diameter of the screw. Required some force to screw it in but seems to fit well now; only time will tell if this is a durable connection.

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From a pure filling a need point of view, this was a bit expensive in time and money, but I just had to try it and enjoyed the process. On to a future with free/open modeling tools, model libraries and affordable 3d printing!

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