TS100 Soldering Iron replacement shell

thingiverse

A few weeks ago my TS100's shell broke around the power jack, so I decided to design and print a replacement. After MANY iterations this is what I could come up with. As far as I can see I am the first one to make it. I have released all of the Solidworks files so people can remix it(if you do, please mention me :) ). This wasn't very easy to design, so if you can please throw a coin my way. Features: - No support - No hardware required - Stronger design than the original - The tips are a press fit, so no more strips screws - more of an "Industrial design" which makes the grip better(for me at least) What it lacks: - No protection window for the oled display How to print: -You can choose any material, PLA works fine, but it doesn't have as much give, so it may brake easier. ABS works better but warping might affect some dimensions. - Print the parts how they are laid with 0.2 mm layer height - The cap has a built in 0.2mm support inspired by Maker's Muse on YouTube - use 3 perimiters and 100% infill for the shell, the cap can be 20%. EXTRA TIP: I do not have a heated bed on my printer so I used a 3 layer raft on tape with PVA glue and 2 halogen 50W 12V light bulbs from Pound Land to print in ABS. You just have to position them on the ends of the parts that are furthers apart, so that the lights warm them up while the extruder is printing on the opposite side.The prints turned out good and I am actually impressed, but its really sketchy and I would not recommend it. I'll leave a picture at the end. I had to wear sun glasses while working and I still got dry eyes. EDIT: printed a version in green el cheapo PLA and it looks and fells and fits sooooo much better than the ABS.