Robust Simplicity

grabcad

Design considerations: CHAMP has to be robust enough, as it will be subject to handle grabbing forces. 3D printing of such part becomes a challenge in a sense that layered structure of the print does not contribute to the strength, thus all engagement between clamp components have to be as solid and as thick as practical. Contact of engaging parts should preferably be over large surface area. Engaging features need to be solid. For the same reasons the following features have to avoided: - screws - threads - pins - teeth - any fine geometry From simplicity point of view ideal design has to comprise of as small number of parts as plausible. Single part design is possible, but requires at least one end of hand rail free of any attachments, as well as installation and removal of such concept onto the hand rail may become cumbersome and difficult due to the friction, and for these reasons single part concept is considered as non-practical. Thus, two part design is a preferred minimalistic design. It was highlighted in the design scope that printed part strength may not meet desired criteria and will most likely fail after real use, meaning that replacement part will require re-printing. Such replacement part has to be as small as practical, to save on material and print time. Print direction: Z-axis of the print (print height) should be parallel with the axis of the hand rail, otherwise if printed in any other orientation, force applied to hand rail will shear the part. Above is my concept of the CHAMP, which may require altering for an in-situ fit. I could have reduced the weight of the design by reducing part thicknesses or by adding extra holes through major surfaces or shortening overall lenght, just for the sake of having lightest concept, but I refuse to go down this path, as even solid material may not be strong enough.