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ForenSeil

World's best printable 2020 extrusion corner connector!

by ForenSeil Sep 7, 2016
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I printed one of these a few days ago in PETG. I did a test fit with extrusions I had purchased for a Hypercube 300 I'm building. It was the proper snug fit on all three axes, but when I pulled the extrusion out of the hole that was lined up with the printer's Z-axis, the bracket started to crack on a layer boundary. I'd recommend standing the bracket up on its corner for printing. (In Cura, I'd start out by rotating it 45° on two axes.) You'll need supports to hold it up (position it so you only have thin supports along two edges) and the supports would benefit from being stuck to a raft, but this will make the bracket equally strong in all three axes. It also eliminates concerns about bridging. If you only have supports along the edges, they'll be easy to clean up. (Use a support blocker to keep from generating supports for the screw holes; they don't need supports.)

For the Hypercube 300, I need more than just corner brackets, so I reimplemented your design in OpenSCAD and extended it to produce the other configurations I'll need. It's also parameterized enough that you can easily make brackets for other square-cross-section extrusion sizes, and it's modular enough that you can join any combination of extrusions at right angles. It's not set up at this point to join extrusions at other than right angles, but it wouldn't be much work for someone to add it if needed. You might want to have a look:

https://www.thingiverse.com/thing:3012597

Parametric Extrusion Brackets
by salfter