Another Same Day Edit: Did you realize that if you print this at 250%, you get a mostly safe pirate ninja star! It's true!
Same Day Edit: OMG, I just realized that this makes a fantastic ninja star! It won't hurt anyone, obviously, because it's not pointy or sharp or anything, but it flies really well! Just print it larger so it's more ninja-star sized.
After 14 years of running straight with no issues, I decided to do a complete manual defrost of my Kenmore upright freezer (Part number: 253.23429100). After the ice in the bottom turned to water, the back-side (shown) started to defrost. And I could see something in the ice. It was like one of those cavemen, frozen (literally!) in time. But it wasn't a caveman, and I had no idea what it was because the ice was so opaque, I couldn't see below it. That was day one. On day two, the ice was all gone, and I realized it was a filter mesh of some sort.
The problem was, the ice had caused the part to deform, and due to its original design, it wouldn't fit into the drain hole. Oh no, what am I going to do?!
After looking up the part on Kenmore's fantastic web-site, I found out that it was called a "freezer drain screen" and it costs $29.51 plus $7.99 for slow-boat shipping (a week or two) shipping and tax ($2.82). So we're looking at $40.32 and I have to wait a week or two for the part to arrive. Whaaaaaaaaat? That's crazy!
SO, I decided to whip out my digital calipers and make this fantastic part from what I knew about it. Long story short(er), 13 minutes and 1.5g of PLA later, I had a perfectly fitting part, and now my freezer is back on its way to being a freezer again!
I want to just say here and now that Kenmore is a great brand. I bought an LG fridge two years ago and had nothing but problems with it. I had to have it replaced THREE TIMES during delivery due to physical damage, which could have come from delivery or the factory, but the point is, my other fridges that I've owned over the years have never had this problem. Then, the LG fridge started to have issues with freezing food in the refrigerator compartment. Finally, after two years, it died.
LG stepped up, after about 30 or 40 calls, complaining on social media, and EIGHT service calls. They failed to fix this thing SEVEN TIMES, and eventually got around to replacing the compressor, which had ultimately failed. They also replaced, completely randomly, almost every other part in the fridge. Turns out, the original problem I had in the first year of ownership was a recall. But because the recall is based on the serial number of a part that was failing, and the technicians that kept coming out were only giving the serial number of the fridge, the fridge "didn't qualify for the recall repair/replacement." After complaining again and again, they finally tried to fix it. But it was just a really bad situation. They kept coming out, replacing parts, and then it would work for a week or two, and then go back to its old freezing-food-in-the-fridge crap.
So the moral of this (even longer) story is: don't buy LG products. They suck. I spent close to $3,000 for this fridge, and it started to fail within the first six months. I'll be buying other products from other companies, and NEVER something that has just come out on the market. Why? Because the reviews for this brand new fridge were stellar...for the first year. After the first year, there were thousands of people complaining.
But please, remember that Kenmore rocks - all the fridges and freezers I've owned that were Kenmore over the years have lasted over a decade with no issues. This rant is about LG, and how they ruined hundreds of dollars worth of food over the course of two years (and I also had to go without a fridge for over two weeks when it finally failed), and they sent me a check for $175 to cover lost/damaged food. That was nice of them, I guess, but I probably lost $500+ worth of food that had frozen over the two years, that I had to toss because it was inedible. Two years of all food in the refrigerator, freezing.
Thanks for listening!
As this is a small part, and I wanted it to be pretty and durable, I decided to print it at High (100µ) resolution, with 100% infill. For a larger part, this would have doubled the time to print, and that would have sucked. But for this, it went from 6 minutes to 13 minutes - still more than double, but still very manageable.
I told Simplify3D to use supports, but it didn't add any. I guess my fillet on the bottom was gradual enough that it didn't matter angle-wise. Please print this so the curved drain holes are on the "top" and the curved "spokes" are on the "bottom," otherwise, you may have to use supports.
Because of the clean design, and soft fillets, along with Simplify3D's ability to design if supports are needed or not, cleanup was not required. I just took the part off the bed, and slapped it into the freezer. Done! I did wait 15 minutes for the part to cool on the bed - which is good practice in general - but it's more important for such a small part with a lot of "spokes," that you don't want the part deformed. That's how we got into this mess in the first place! According to Sears' part website, it's supposed to be flat, which the one I removed wasn't (it was deformed by ice).
Fusion 360 and Simplify3D
I took the damaged part from my freezer, and used calipers to measure all the things. Outside diameter of the star, inside diameter of the star, the distances between things, and the size and spacing of the holes. Fusion 360 does a great job with mirroring, and circular patterns. I was able to put a single hole in the center, and then another hole 5mm or so off from that, and then take that off-set item and create a pattern of eight total holes. Done! 2mm extrusion later and you have a perfectly-fitting part.
If you have a different fridge, with a different size (but same shape) drain hole, just let me know what the outer diameter of the part is, and I can make another version for you and your fridge. Just don't forget to let me know the make, model and part number of the fridge itself, because I'd like to credit you and make this easier to find for others looking for the same thing. This part is 35mm O.D. if you're comparing. But it's such a fast print, you could just download it and print it out on medium in six minutes, if you thought it was close to what you have. Easy peasy!
I used Simplify3D to perform the slicing and dicing and outputted that file to my handy dandy Toshiba FlashAir SD card over Wi-Fi.