UItimate Bar End Friction Shifter

Major Update 09/05/26:

Uploaded a new and vastly improved design. Massively improved shifting performance and reliability from redesigned friction mechanism. Better print-ability and strength.

This is an almost fully 3D printed friction shifter. This is a project I have been working on for over four years, on and off. This model is the latest and greatest iteration! It uses PETG plastic for its favorable properties but also its cost and finish. The parts are intended to be printed without the need for heavy post processing. Supports are also not necessary, but may help with overhangs depending on your printer. The friction surface is done by using a stack of belleville spring washers, flat metal washers and nylon washers, which give a buttery smooth operation and feel while holding tension. I have used this specific shifter daily for more than six months, without issues. It works great!

I use this shifter on a 3x7 setup,  so the cable range I need is only small. I expect it should be possible to use the shifter with an 8 speed setup, potentially 9 speed. For 10 speed or above, you will almost certainly require a larger shifter barrel size. You can either edit the SolidWorks files yourself, or contact me and I can try to make a wider range variant if necessary.

Features:

• The shifter can be completely added or removed from the bike, without needing to ever remove the derailleur cable run. This makes tinkering, testing and replacing the shifter easy and painless.

  • The dual holed cable guide on the shifter itself allows the shifter to be removed.

  • The cable guide on the shifter mount (shifter pod) allows removal of shifter pod.

• The use of a quill-style clamp provides a snug fit for different bar end diameters (can be easily altered if necessary for your handlebars).

• Cheap as chips to produce! (less than 1.50EURO per shifter)

• Uses a specific washer stack so shifting performance is always good and consistent regardless of printer.

• Belleville conical washers are used to hold the bolt tension, so you do not need to tighten the shifter after every ride.

• The print is reversible, in order to print a shifter for your front derailleur it is only necessary to flip the models in your slicer. 

• No/little post processing required.

• The bolt for the shifter can be tightened using a small hex wrench, or by hand (if a wing nut is used), so it can be easily tightened out on the road.

Assembly Instructions:

Link To YouTube Build Video

Print Settings:

I printed on my Bambu Lab A1 with a 0.8mm nozzle diameter. This provides more strength then using a smaller nozzle. A 0.6mm nozzle should also work perfectly fine, a 0.4mm nozzle is serviceable but might have some issues with snapping the shifter under load.

• 0.12mm layer height in general

• 100% infill

• 4 wall loops

• No supports (although supports for the shifter pod and shifter itself can help with the overhangs) 

Hardware (per shifter):

• [1x] M5x60mm hex head bolt

• [1x] M5 nut

• [1x] M5x10mm washer

• [1x] M6x25mm bolt

• [1x] M6 nut

• [4x] M6x12x0.5mm metal washer

• [4x] M6x16x1mm nylon washer

• [2x] M6x12.5x0.35mm belleville compression spring washer (Ali Express NL Link)

Some other notes:

PETG should be fairly easy to print. This shifter may not last quite as long as standard metal shifters, but you should not need to worry about durability! I would strongly recommend not using PLA as I do not trust the reliability of the material in this application. In my testing PETG is ideal, but a carbon nylon filament may also work for extra durability (but watch for surface finish issues). Watch the assembly video for clarity about the washer stack, it is important that the conical belleville washers are in the correct orientation. 

Feel free to ask me questions, or if you would like me to alter the model slightly - I would be happy to.

Have fun!

Harry