Thorsten Wilms wanted to attach a headlight to his new bike. He bought a Busch & Müller Ixon Pure bike headlight with two clamp delivered but both were not fit for his bike, one was too small, another was oversize, and when he put it on he found the lamp was in the wrong direction.
Fortunaly as a freelance industrial designer Wilms was able to design a 3D model of the "sled" for the clamp which could set the headlight in reverse. He used free software parametric solid modeling application FreeCAD to design a 3D model and print it out at Shapeways using their strong & flexible material. In just 10 days he received this self-designed "sled". The 3D printed sled has an excellent precision, though the quality of the surface and the corners are not perfect but it fits pretty good with original clamp. He made a tunnel with the smaller diameter of the screw and it works - it required some force to screw it in but it fits very well.
The 3D printing costs him € 17.73 including $ 12.05 for the part and $ 11.31 for shipping. This is a nice case showing that with a little creation and designing skills, 3D printing enables everyone to create their own printable designs and parts on demand as needed.
Photos credit: Thorsten Wilms
Posted in 3D Printing Applications
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