3D Printed Breakaway Connectors for Assembly and Maintenance

grabcad

1) How many times have you dropped a screw while working in an area with limited access? 2) How many times have you had to remove multiple parts just to get to the one that needs repair? In support of "Design for MAINTENANCE," I am presenting examples of how 3D printing can be used to create breakaway connectors for easier installation and repairs. The connectors are 3D printed along with their components knowing that they will be needed in the future. In the first example, setscrews are 3D printed along with a shaft coupling. They are held in place with breakaway supports (shown in red) until ready for installation. The setscrews could have been printed pre-installed in the threads, but current technology is often not sufficient (screw is either too loose or it is fused to the threads). In the second example, a "universal joint" consisting of a flexible center (yellow) connected to rigid ends is shown. Here, non-threaded pins are added to the design to hold the components together with breakaway supports (shown in red). Should the flexible portion need replacement, the pins are broken off, the center replaced (green), and traditional screws are used to secure it in place. This could be useful for a field repair where access and time to disassemble are limited. Sacrificial supports are no longer just for 3D printing - they can now be integral to the installation and repair of the part...