Gaggia Classic Hat for Gaggiuino

This is for the Gaggiuino project.

Instead of printing the screen mount and plate, I wanted to print an extension (or hat) that I could mount the display in that would also give me extra space for the wiring and components for the Gaggiuino project.

This will work for the Gaggia Classic and Gaggia Classic Pro.

This is a remake (not a remix) of another project I saw. That project was basically unprintable on an FDM style 3d printer, so I recreated it from scratch in Fusion to be easily 3d printable with only a tiny bit of support material. 

I have uploaded all files you would need to make this your self and even modify it if you want.

To print this, you'll need at least a 256x256 build plate, and a printer which can at least print PETG (preferably ABS or ASA). Do not print this out of PLA. If you do, the heat from the espresso machine will warp the plastic.

This is two separate prints.

• Because these are quite large pieces, I highly recommend using glue and printing with brims, no matter what material you print with. These parts are prone to warping, so if you don't have an enclosed printer, be sure there are no breezes by your printer.
• Print the ‘hat’ part upside down on the build plate, no supports. There is a triangle shape that will print inside of the display opening. When it is finished printing, just snap this out with your fingers - it'll break away easily leaving a clean surface.
• Print the ‘base’ part right side up. This requires supports - but there will only be a tiny bit under the front of the part.
• To install the Nexion display to the front, you'll need to add brass heat set inserts to the four holes. If you didn't want to do that, you could probably just tape it in, as long as you use tape that is heat resistant. It shouldn't get too hot by the display, but it will get warm. Don't use glue though, or else you wont be able to remove the display to access the sd card.
• You might need the tube extension as well.
• The two pieces, even though pretty big, only use about 200-250 grams of filament. And they print (on the P1P at least) in about 6-7 hours total.

Once printed, the two parts should just snap together, no screws needed. You will want to screw the top of the gaggia to the top of the hat. You can also screw the base into the gaggia it self, but this is not needed.

I printed this with an enclosed p1p that had a heated chamber. If you print on an open frame printer, I suggest using PETG.

I used Flashforge ASA from amazon to print mine. If you have an enclosed P1P and a similar filament, you can print my Orca Slicer prints directly.

If there is interest, I can modify this model to make the lid sit below the surface like it does in the gaggia normally. This will probably require supports to print though, which is why I didn't design it this way in the first place. Also, I could probably make the display mount without brass inserts if that is something anyone wants. Or, feel free to change the model your self and let me know. Then I'll link to your updated model from here.

Notes and future updates:

• I'm noticing some warping around the back (see pictures). I'll try to add some model features to prevent this.
• Even though it is not required to attach the hat to the gaggia, it looks like it is going to be recommended because otherwise it doesn't really sit flat because of the wires. To that end, it looks like I am going to have to redesign the bottom so it fits into the slot on the gaggia.
• The metal top doesn't sit as flat as I'd like, so I'm going to have to add a slot for it to fit into.