Zephyr 350 Caravan Table Hinge Bracket

Zephyr Caravans were made in New Zealand circa 1987. They were of durable design, but after 40 years some parts can break through age.  The interior small hinged table attached using a pair of nylon brackets.  The brackets can break under certain conditions but can no longer be purchased.

Its worthwhile replacing the part if the van is in good condition.  These brackets can be made using FDM printing at an incremental cost (excluding modelling and shipping) of < $NZD 20 per pair.  They could also be made using SLA or MJF printing, but at a higher cost.

This model was made by reverse engineering from an original part with no modifications.

They are best made by printing with a strong non-brittle material.  I used Essentium HTN based on Nylon ( PA 12).  Its  slightly flexible, very low friction coefficient and very strong.  
Its likely overkill and the material isn't at all cheap, but the cost of the brackets pair made with this material is reasonable because the brackets are small in size.

Print settings and notes:

• Based on Printer: Prusa MK4S with 0.4mm CHT Nozzle and Prusa Slicer 2.9.2. Careful calibration of belt tensions is needed for good print quality and dimensional accuracy
• Bed: Satin PEI, with Magigoo PA applied
• Layer height: 0.15 mm
• Speed: ~80 mm/s (+ MVS setting of 6) = Slow
• Perimeters : 4
• Supports: Yes (for the screw holes)
• Infill: 20%. Could go higher.
• Material: Essentium HTN.  Manufacturers recommended filament profile settings, with User calibration of Extrusion Multiplier and Shrinkage compensation. Carbon Fibre or Glass Fiber version of this filament could also be used but $$.
• The printing temp for this material is circa 280C, with Bed of 80C but you need to tune this settings to suit your own conditions.  
• The material is hygroscopic, so you need to dry it and maintain drying throughout the print.
• Post printing, the holes can be cleaned using precision 5mm and 5.2 mm drills.  Use original countersunk screws for mounting.