Snooker Cue Extension (modular)

This modular Snooker cue extension should fit cues with a butt end diameter of roughly 30 mm (maybe a bit more). 

I printed it in PETG-CF and it works good, very stable and lightweight. The most part of the model was printed using 2 walls and 0.6 mm line width with 0% infill. Some parts were reinforced by using modifiers to add more walls and/or infill (see screenshots or project files for Orca Slicer).

Rotating sleeve:

• Layer height: 0.2 mm, Line width: 0.6 mm, 2 walls
• 6 bottom and top layers, 0 % infill
• no modifiers
• use scarf joint seams to minimize Z seam

Clamp:

• Layer height: 0.2 mm, Line width: 0.6 mm, 2 walls
• 20 bottom and 6 top layers, 0 % infill
• modifier 1:
  • lower 15 mm, add additional walls (I went with 6 walls) and 10-15 % infill to enhance stability for heat insert
• modifier 2:
  • middle part, beginning around 15-20 mm under the bottom surface of the conical shape where the butt end of the cue will make contact with the clamp, add 10-15 % grid infill for better bridging

Butt 1 & 2:

• Layer height: 0.2 mm, Line width: 0.6 mm, 2 walls
• 20 bottom and 6 top layers, 0 % infill
• Place a cut at the top layer of the hex screw to be able to insert the hex screw and then glue the separate parts parts together. Use connectors for centered connection when glueing (see screenshot). You could also print the model with a pause at the right layer number to insert the screw during the print, but that would require you to use supports as well.
• modifiers as shown in the screenshot, add additional walls and some infill for enhanced stability around the heat insert and hex screw
• Butt 1 has no chamfer on the screw end, to make for a seamless connection between the clamp and butt 1. Butt 2 has chamfers on both ends, for better grip feeling and for optical reasons.
• To add more length to the extension, just print another butt 2.
• You could cut the butts in the middle or so and add connectors in the slicer for glueing in case you don't have a printer with enough Z height.

Hardware needed:

• 2x M5 heat inserts (7.1 x 9.5 mm)
• 2x M5 x 16 mm hex head screws
• super glue if you print the butts in cut mode
• I added a bit of grease to the outter parts of the clamp where the sleeve is forced onto the clamp (the triangle shaped pertrusions at the top of the clamp) and to the threads