Scooter Ignition Cap - Kymco (2004)

thingiverse

I picked up a used 2004 Kymco Agility 125 scooter last summer. After the first month the ignition cap came loose because a tab broke off. This was a great opportunity to solve a real world problem with 3D printing. The process was pretty straight forward. I had to make 3 prototypes in getting the measurements just right. I doubt there will be many prints made of this item, but at least at some point in the future it will substitute a broken part. If you happen to print one for your own scooter, drop me a line. Print Settings Printer Brand: Deltaprintr Printer: Deltaprintr Kit Rafts: No Supports: No Resolution: 0.4m Infill: 30% Notes: This model provided several successful prints without supports. I used Hatchbox Blue filament. If the print doesn't fit in on the scooter you can try to file down high areas that go around the shaft. If that doesn't work, try scaling down the print slightly. It should fit snug around the ignition shaft. How I Designed This I was working at the Foundry Makerspace and wanted to provide an example of a real world 3D printing problem for students in the Robotics Club. To help them understand the design process I brought in the original cap and used calipers to measure every nook of the part. I then used Sketchup Make to model the par highlighting key steps. Instead of using 3D text, I thought I would go high-tech by using standard icons for the lock and power positions. When I was finished I exported it out as an STL file. Another colleague had just purchased and received a Delta Printr Go 3D printer. I had told him about it during my NYC World Maker Faire trip on 10/1/16-10/2/16. It took a couple of prototypes because of slight variations in printed material. After the 3rd try it the part fit perfectly. I was impressed that the icon showed up on the print.