Project Rigel CHAMP

grabcad

Before I started with my concept I didn’t think about the restrictions of 3d printing but about the opportunities and advantages 3d printing enables. The “Nasa wrench” is the best example: it can only be 3d printed, not be made by conventional means and it can be used straight from the printer. With this inspiration, I tried to think “out of the box”, I designed prototypes and after a lot of testing and adaptation the “Project Rigel CHAMP” was the result. It is one of a kind! Advantages: 1. Easy to attach to the handrail and remove (can be done with one hand) 2. Rigid connection to the handrail: high clamping force in x and y direction, no slippage along the handrail length, no rotation around the handrail. Tolerances of the print or/and handrail are no problem. 3. Seat track connection consistent with provided dimensions (same position as the old clamp) 4. No sharp edges (safe to use) 5. Optimized for FDM 3D Printing: 0,3 mm clearance between moving parts, overhang deg. < 45%, optimized for 0,25 mm layer height, no support, no raft 6. One single print, two parts: • no assembly required • can’t be dissembled • no parts floating around • can be installed straight from the printer • no precious astronaut time wasted 7. Tested with real 3d-printed prototypes (PLA test prints, but ABS should be no problem) 8. No pins (concepts with hinges or/and pins: the pins are always the weak spot) 9. Easy adaptation (increase or reduction) of the clamp force with the slopes. Depending on material properties, print parameters and 3d-printer the slopes can be modified in the CAD file. 10. Intuitive use (no manual needed) 11. Clear position that the clamp is locked (and always the same clamping force) 12. No inadvertent disconnection (Difficult to accidentally disconnect) 13. Dimensions of the clamp consistent with the requirements CAD Software: • Creo Parametric Academic Edition Prototypes: • CTC Desktop 3D Printer (Makerbot Replicator / Flashforge Creator Clone) • PLA 1,75 mm (Filamentworld.de Schneeweiß) • 0,25 mm layer height • Top Solid Layers 4 • Bottom Solid Layers 4 • Outline 2 • 15% Infill • Simplify3D 2.2.2 Principle of the clamp force: Rotational movement of the latch-> elastic deformation of the latch because of the slopes (Fy/Fx) -> clamp force in x and y direction Spend all my time designing, printing and testing, so no fancy animations (please watch the youtube video instead) Questions and comments are always welcome! Project named after the seventh brightest star in the night sky and “Riegel” means “latch“ in German Project Rigel CHAMP V7 Simplify3D Toolpath: https://www.youtube.com/watch?v=j8d8cOu6-VY&feature=youtu.be (Renderings and video are version 7) Update version 9: • Shortened the latch (no space between the end of the slope and the housing in the closed position) • Changed the angle between the housing and the latch Update March 11, 2015: Thanks for the comments! I updated the latest version (10), with the max. clap force Fx (max. slope possible with this design) I will test the design the next days (hopefully with ABS) Think more about the opportunities of 3d printing. For example: Open community of designers, open source designs and a 3d printer on Mars :) There will be so much to design that everybody gets his design to Mars :)