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REMIX: Cygolite Metro Handlebar Bracket Clip Replacement
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Modified for clip and mount design improved strength and resilience.
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Updated at source:
Model information
- Source
- Printables
- Category
- Outdoor Sports
- License
- Creative Commons — Attribution — Noncommercial
ORIGINAL MODEL FAILURE MODE:
Firstly, BIG THANKS to @SeanK_97580 for the original model!
After a year-plus of good service holding my Cygolite Metro in place on my daily commute, the light mount failed at the clip + screw hole interface.
This proved to be the weakest point of the original model, with the entire load of the light and vibrations going through a very small cross section of material around the screw:
MODIFICATIONS:
- Redesigned the CLIP so that the screw no longer passes through it.
- With the screw in place, the BODY sandwiches the clip securely in place against the handlebar clamp. The clip cannot be removed without removing the screw.
- Increased CLIP thickness for durability.
PRINT ORIENTATION + SETTINGS:
- Using PAINT ON SUPPORTS, print CLIP in the orientation as shown below for best sheer strength:
- Print BODY without supports in the orientation as shown above (no supports required).
- LAYERS: 0.2mm Structural (Prusa Slicer)
- PERIMETERS: 4 perimeters recommended for strength.
- INFILL: 15-20%
- FILAMENT: PETG recommended for strength.