I wanted to print a replacement leg for a SleepNumber bed. I found this excellent model, https://www.thingiverse.com/thing:3339457 but it does not fit the MK3 build volume. Using nothing but PlusaSlicer and a little trial and error I managed to cut the leg into two parts, add a joining peg for support, and print the whole design in one go. The high level process was:
- Load the part
- Create ‘peg’ holes
- Modify the part → Add negative volume → cylinder
- Adjust the size of the peg holes appropriate to your needs. I wanted a strong peg so I made them about ⅓ the size of the leg.
- Optional: Unlock the object dimensions and make the cylinder oblong to enable the parts to be locked into a given orientation. This was not required for this example. Be sure to note your dimensions, you will need them later. For this project they were 30x45x50.
- Move the modifier to the correct spot. This may take some trial and error. For this project I made the modifier have the same X and Y coordinates as the leg and changed the Z to move the ‘peg’ higher into the model where the cut would be.
- Perform a cut on the model where the middle of the peg is. Use ‘keep upper’, keep lower', and ‘rotate lower part’ options.
- See if the cut and peg seem like good locations. Adjust the negative volume and cut locations as needed until you have what you need.
- Add a shape → Cylinder and use your dimensions from above. I cut 1mm off the height to allow for fit and glue.
- Slice for strength and print. I used 6 perimeters, 20% infill, and printed in PLA+. I think it was overkill.
Notes:
- The peg is 1mm shorter than the holes to allow for glue if you want
- My printer is pretty well dialed in on dimensional accuracy (prints are almost exactly the right size) and the fit of the parts is excellent. So much so, I probably didn't need glue. If you have a hard time with the fit, print the plug slightly smaller and glue it in place.
- If you are worried about strength, you may want to modify the peg to print sideways for added strength. To do this I would just shave one side down flat, you don't need to have a completely filled peg pace IMO.
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