2020 extrusion hinge outside corner mount 200 degree opening

I needed a hinge to mount a .25" polycarbonate ( roughly .220" thick ) to the front of my home made enclosure. The hinge mounts to the outside edge with 3x m5 bolts, allows a 6mm overlap on the front edge of the 2020 extrusion, and allows for a .125" weather strip pad to have 1/32" of “squish”. The panel side hinge mounts with 3x m4 bolts and the sandwich plate allows m4 nuts to lightly press in. The cap slides over a rod and allows for a cross pin to be inserted to secure the pin. I had some .25" aluminum rod handy ( roughly .257" diameter ) so I used that for the hinge pins. 

Solidworks shows 202º of free rotation before any collision which allows for the doors to easily achieve an opening of 180º.

I used PLA+ for the outer pieces, and PETG for the sandwich plate on the inside. 

.6mm nozzle 

.2mm layer height

20% infill

5 vertical walls

5 horizontal walls

no supports needed. 

If you wish to print this all in the same material, A sample layout has been provided for 4 assemblies. 

Enjoy