Modified corner side gussets for 10 series aluminum extrusions 1" square

I found Bill84s corner bracket and printed out a pair for my new printer but I was going to be using bolts instead of screws so where his support bracket in the back was wouldn't work for me as I couldn't get a socket in there (the irony is after all the modifications I ended up using screws) so I started modifying it, I cut the back support away but needed some sort of extra support in the corners of the brackets so I connected the tops then thought they would look better curved, then I was looking at it thinking "what a waste of plastic" and thought about cutting a triangle out but it wouldn't look very good and would give three sharp edges to crack at so I decided to cut circles out, it lessens the plastic used to save on plastic which causes it to print faster also, is extremely strong, and looks pretty cool.

I included the inside corner gusset that I created but did not end up printing it or using it but included it if someone wants it and the sketchup file.

Update 8/29/2015:

I made the bottom corners for a 0.5" gap but when putting my printer together I decided I wanted to use a power socket out of an old PC power supply but it was 0.75" tall so I made two new bottom corners with a 0.75" gap, I found a minor issue with the 0.5" ones so I fixed those as well, enjoy.

Instructions

I printed them in ABS and PLA, PLA worked really well and was hard but I don't have air conditioning and a marble maze got hot enough for it to soften so decided ABS was a better choice.

if laid flat the piece that will print up will split easily, fuming the ABS helped but I am going to print them at an angle next time, if angled at a 45 degree angle on the top cura only shows support at the bottom and no where else but I have not tried printing it but I have not tried it yet, that would fix the easy to split part, lol or use a washer. ;-)

ABS

0.4mm nozzle

0.2mm layer height

40% infill (probably should have went solid)

Category: 3D Printer Parts