Sleep Number Bed Leg

thingiverse

Got one of those fancy Sleep Number beds but the leg broke? You are in luck! I was asked over the holidays if I could print a bed leg to replace one that had broken. They sent me the leg to turn into an .stl and to print. I didn't make the copy exact with the taper on the lower part of the leg because the goal was to make something strong enough with ascetic taking a back seat. The design matches the original with some reinforcing on the back. There are three designs uploaded. One regular solid file and two hollow with different wall thicknesses. The solid one should be printed with 50% or higher infill but that might run almost an entire spool. So to keep material use limited, the hollow files are designed to be filled with that canned expanding foam. There are holes designed in the top and bottom of the part to allow for the foam to be sprayed inside. Supports will be needed on the outside overhangs but not inside. Internal supports will interfere with the foam and make the part weaker. I figured it wouldn't hurt to throw the design up here. I really don't know how many times I've saved myself many hours of CAD work by simply searching for something here. UPDATE: I received feed back and the current design should fit very well. The expanding foam technique worked great and completely changes the part from squishy to cement like. Be sure to allow the foam to solidify for about a week.