Screwdriver for Melissa & Doug Take-Along Tool Kit

This is a replacement screwdriver for the Melissa & Doug Take-Along Tool Kit Wooden Toy (https://www.melissaanddoug.com/take-along-tool-kit-wooden-toy/494.html). As you can see from the picture, the original had an unfortunate encounter with a dog.

Design

I designed it in two parts, the shaft with driver tip and the handle. The shaft enters 40 mm into the handle and screws into place. The main benefit of this approach is increased strength (as a single piece this would be a weak spot prone to breakage). Additionally, it allows you to easily use two colours for the filament. Use some super glue on the threads to permanently join the two pieces.

I've made two improvements to the original design: the tip is chamfered at each end to make it a bit less pointy, and the handle is chamfered where it meets the shaft for the same reason.

Printing Instructions

Handle: Print open end down with a brim. There is an allowance at the top of the threads for bridge flow, and no one will ever see it once it's assembled. I included a .3mf file with variable layer height for the handle cap.

Shaft: Print threads down at a 15 degree angle with supports on build plate for about half the thread length. This will ensure the layers are not completely aligned with the axis of rotation, and will make the part stronger. I included a .3mf as well as the .stl so you can see how I did this.

I used PLA for the shaft and and handle.

Notes

I designed the model in OpenSCAD and it's fully parameterized. If you'd like a variation on this with different dimensions, just message me.