xHain-hackspace / ledbar-caps

Protective/supporting caps for creating triangle-based structures using our LED bars and rope.

ledbar-caps

Protective/supporting caps for creating triangle-based structures using our LED bars and rope.

For camp 2023 we wanted to build a structure using LED bars based on pipes we already have and rope running on the inside of the pipes. 3 pipes will be assembled to form triangle and the triangles will be assembled to create shapes. For this, the ends of the pipes need a proper load bearing area and also some protection for the cables running on the outside. This repo contains 3D printable end caps which will hopefully do that job.

Design/Test Notes

'cap_v4' Design

• WIP, the version we are currently testing/improving

'cap_v3' Design

• the version we used for CCCamp in the end
• changed top side from round to 30° edge as else the rope and the round cap create a turning moment that pulls out the caps
• this fixes that round cap makes rope too far off pivot point, so cap wants to twist out of pipe
• also makes everything a bit more stable (line load vs. point load)
• threading rope works OK, a bit fiddly for multi-rope pipes
• still kind of fiddly to set up with all the rope threading, but worked OK
• still very sturdy with 60% infill
• prints completely without supports

'cap_v2' Design

• chamfers make cap nicer and more cable friendly
• round cap makes rope too far off pivot point, so cap wants to twist out of pipe
• 'cap' design would probably also have this problem when tested with rope
• inner diameter looks good
• chamfer on inner hole makes first layer hard to print and stick for middle portion (single line circle)
• threading rope seems to work nicely
• still sturdy middle portion (100% infill)

'cap' Design

• sits well on pipe
• cable protection ok but, sharp edges should be chamfered
• needs support, but we might be able to drop this
• hole in middle needs to be bigger
• threading rope might be difficult because of edge, might need chamfer on the inside

'goldcap' Design

• currently too small inside plug (radius/diameter mixup by accident)
• does not really protect cables, needs to be longer
• prints faster
• needs support
• hole in middle needs to be bigger
• threading rope might be difficult because of edge, might need chamfer on the inside