I love this switch guard idea, and give all credit to
@chrsbe.
@Stu_Barnes and I started communicating with him in early March about using his design to produce something that might become available more widely via the forum store. He generously blessed the idea and we tossed ideas back and forth for a while. Real life caused a few delays so here we are in May and I am just now showing off progress.
My goals were different from
@chrsbe's original criteria, since I set about designing these for controlled manufacturing instead of posting the STL for anyone to make. The main change I sought was to reduce cost and complexity by pursuing a single piece design that could be snapped into place instead of using screws. This was tricky for lots of reasons (as the original inventor encountered as he refined his own design). The only chance of success comes because we would have control of material and printing parameters, so I can implement some details that would probably not work without control of the manufacturing process.
After numerous prototypes, the 1-piece design below emerged:
I am printing in PETG-CF on a textured build plate, so I get very good bed adhesion and do not have any problems with the angled print orientation shown above. Again, not something I would trust to work for most people if this design was provided as an STL. This angled layer orientation also gives robust strength to the snap-on and click features where they bend, and also allows for nice surface finish over the entire 'handle' end of the part.
I really like the way the original 2-piece design operates, especially the satisfying 'click' into both the closed and open position. I worked for a while to accomplish a similar feel and sound with the attached 1-piece design. The following images show the original 2-piece above and the 1-piece design below:
If there is sufficient interest,
@Stu_Barnes has indicated willingness to produce and ship these via the Forum Store. Let's hear it.
Again, thanks for the inspiration
@chrsbe !
