* Henry Baker <hbaker1@pipeline.com> [May 27. 2016 18:43]:
People are using 3D printers more & more for prototyping.
I received a small electronic gizmo which plugs into a USB port whose plastic case was 3D printed.
The problem is, the plastic case keeps falling apart, due to the relatively poor tolerances of current gen consumer 3D printers.
It seems you want something for actual use. Hence no PLA, instead use ABS. If a consumer model is used, the operator will need some skill (and quite possibly luck). ABS prints tend to warp, especially with cheaper printers. If you can have what you want made from a more expensive printer your chances are much better, the operators will know very well what to do for every requirement (my Uni bought one for 750 K Euro recently, they had to take the wall out of the room to deliver it with a crane; that one can do metal (sinter) prints with close to no restrictions). Alternatively, send me the STL file and I'll talk to the guys that have bought a very decent printer that is good with ABS. Payment is beer (this is Bavaria), I'll take care of that. Mit besten Gruessen, Joerg Arndt
So...
The challenge is to come up with a way to print a little rectangular plastic box -- probably in 2 pieces -- that can be put together in such a way that it won't fall apart under normal handling (e.g., carrying it in your pocket banging up against your house keys), but can still be easily disassembled w/o any special tools, screws, etc.
Note that current 3D printers have the following characteristics:
* the plastic isn't very strong and isn't very flexible, so "fingers" that interlace may be too weak and may easily break off.
* the plastic deforms slightly during printing, so registration isn't terribly good.
* the resolution in different dimensions is different, so the tolerances have to be quite wide.
If printing the box in 2 pieces won't produce a satisfactory answer, how about 3 pieces?
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