Cable Saver (parametric .blend)

I found this model by “kdv0403” on Thingiverse, and I really liked the concept, but I was having no luck customizing the model on my own with their provided file. I searched around on Printables and Thingiverse some more, but I couldn't find any other parametric cable savers like that. So, I decided I would just make my own.

I don't really know SCAD. I'd like to learn some day, but I make most of my stuff in Blender. So I decided to just make this in Blender too, since it's more familiar to me. The file is set up with parameters that can be entered, to dynamically change the shape of the model, just like in SCAD. Only problem is that the final meshing process is a little clunky, but ah well. 

If you want me to upload a new cable size, feel free to leave a comment with measurements and a photo, and I'll try making time to add it to the list!

Files

The premade models I've uploaded include the main dimensions in the name.

The names use the following pattern, 
(where Cnnctr = Connector, End = Cable End, Cbl = Cable):

[Cable Name] Cnnctr<width>x<height>x<length> End<width>x<length> Cbl<width>.stl

Printing:

This is a fast and easy print. No supports are needed.

PETG is ideal for this model due to it's flexibility and strength. However, PLA seems to work fine as well.

There is a small 90 degree overhang on the top of the connector. This prints fine for me, but it may sag somewhat. If it does, you might need to increase the height tolerance for your custom connector. You can use high part cooling and low speed to get it to print better. It may also help to set infill to print before perimeters.

Measuring

These are the main measurements that need to be taken to get a fitting cable saver:

You may also need to change some things like the bevel, depending on the shape of your cable's connector. 

Tolerance

If you customize this model for yourself, or want to compare your measurements to the models I've posted, these are the tolerances that worked best for me:

• Connector width - add 1mm (for rounded USB C connectors, at least)
• Connector height - add 0.3mm
• Connector length - use exact, or use less (to give room for phone case, for example)
• Cable end width - use largest measurement
• Cable end length - use exact
• Cable width - use largest, plus ~0.1mm (maybe less for a bendy filament)

Customizing

If you are familiar with Blender you may not need any tutorial, but I have provided detailed instructions below so that anyone can customize this model, if they'd like to.

1: Open the .blend file.

2: Move the parameters to modify the model. 

Open the transform panel to specifically set the parameters. (if you don't see the side panel at all, pressing n on the keyboard shows/hides it. you'll have to also click the ‘>’ to drop down the full panel).

3: Measure your cable and add your tolerances to find out the dimensions you need. Enter that final measurement (in millimeters) into the yellow property of the transform panel. 

For example, the screenshot below shows that the “cable end length” is set to 6mm. 

(the “highlight” is actually a keyframe. therefore, you can reset everything back to default by moving to a new frame in the timeline)

4: Once you have set the parameters the way you want, you can get the result from the “rendered model” object. 

4.5: Place the duplicate model in the scene.

5: Convert it to mesh.

6: (skip if you already have 3d print toolbox) Unfortunately, blender sometimes makes some mistakes when adding/subtracting geometry together. This is an easy fix, but we need to use the built in “3D Print Toolbox” plugin to do it, and it's disabled by default. So, we have to enable it:

7: Repair the mesh with 3D print toolbox

(In my testing, 3D Print Toolbox has been able to automatically fix errors in this model without issue. However, sometimes it isn't able to automatically fix it, and you may need to manually repair the mesh. 
Usually this is as easy as going into edit mode (tab), selecting non-manifold edges (click the non manifold edges button in the 3D print sidebar to select them), and then hitting F to fill the hole.)

8: Export your model!

By the way, there are a lot of additional things that can easily be changed about this model by changing the modifiers in addition to the parameters. Feel free to explore around if you need more options :) and let me know if you have any issues!

This file and the instructions were made in Blender 3.5; If you are using a different version (like 4.0+) the menus may be a little different, but I think it should still be similar.