Randco Nut Buster 2000

I needed an ergonometric heat insertion tool, that is horizontal in design, that supports brass nuts placed upon the TS101 iron heat insertion tip without falling off (to help deal with effects of essential tremors). I needed a design that is easy to insert/remove the iron and provides sufficient travel to support larger objects.

While I was noodling the pregnant idea around in my head, trying to avoid rocks and other clutter, I decided to create a sort of ‘steampunky’ vibe with gears, levers and slides.

Instructions for assembly and use:

1. Route the soldering iron power supply wire up through the bottom of the tool, through the hole in the slide and attach the cable to to iron
2. Gently press the iron down into the slide (it will clip in place)
3. Attach the appropriate (3mm) heat insert adapter tip onto the iron (I use the CNC Kitchen pack)
4. Ensure the power cable has sufficient extra length for the full slide travel before securing it into the provide cable holders on the bottom of the pedestal feet (routes to the rear)
5. Insert the pedestal rails into the slots on both sides of the mechanism support plates, position to the proper movement depth and secure with the two rail pins
6. Heat the iron to 200C (for PETG)
7. Use tweezers to add a brass heat insert nut onto the iron tip (ensure correct direction with knurled shoulders toward the iron and the narrower sleeve forward)
8. Hold the object against the pedestal plate and slowly rotate the spur gear forward to set the nut into the plastic
9. Depending upon your work surface, you may need to add anti-slip pads to the bottom of the pedestal feet to prevent slipping

Parts for assembly:

1. 3mm Brass heat insert nuts 
   1. H8, 6 each for securing side supports 
   2. H6, 4 each for interconnect plate
   3. H8, 6 each for pedestal feet
   4. H8, 4 each for pedestal rails
2. M3 Hex button head cap screws
   1. 12mm, 6 each for side supports
   2. 6mm, 4 each for interconnect plate
   3. 12mm, 6 each for pedestal feet
   4. 15mm, 4 each for pedestal rails
3. TS100/101 soldering iron
4. Heat insert iron adapter tip with interchangeable nut tips

Parts sources:

1. Heat insert nuts
2. TS101 soldering iron
3. TS101 adapter tips
4. Hex button head cap screws

Slicing/printing

1. I used Prusa Slicer on an OPXL 5H printer (.4 HE, input shaper, either .20 or .25 layers). As such, you'll need a 360x360 bed for printing.
2. I used Polymaker PETG for all parts
3. I used Hatchbox white PLA for the support interface layer using the .20 soluble interface profile (it provided the best adhesion/release combined with Polymaker PETG)
4. Three parts required interface support, the iron slide, the spur gear shaft and the rail pins
5. I've included PrusaSlicer projects for all parts, that include mouse ears and appropriate settings for the PLA interface layer (where appropriate)
6. To maximize part straightness, I position long object towards the outside edge of the print bed
7. Although heat insert holes are set to 4.2mm, you may need a 4mm drill to clean out the holes
8. The pedestal plate has a text modifier for the “Nut Buster 2000” naming

Other notes

1. In the future I may design additional pedestal plates with adaptations for stabilizing cylinders and round objects
2. I thought about adding an auto-retract mechanism, but I'm still debating the idea