Bugaboo Donkey Brake Pedal

I 3d-scanned the original pedal that broke and modeled a replacement in Fusion 360. The shapes of the pedal are a bit simplified, but all essential geometries from the original are copied to this model. Included in the files are different print combinations (instructions below), the 3d scans and a .step file if anyone wants to modify it. 

The complete model is quite hard to print in one go. The pedal becomes strongest with the part on its side. But that makes the axle too weak. Eventually I had to separate the two in order to succeed with my single extruder printer. A SLS printer wouldn't suffer from these issues. It is important to print the axle with a very stiff material, hence the CF recommendation. Print with outer wall first for dimensional accuracy. A 8mm long steel pin with 4mm diameter is needed. Press it in the 4mm hole together with a suitable glue. 

Print suggestions, with level 1 most difficult:

Level 1. Complete pedal model. Print the entire model with a SLS printer or printer capable of printing CF reinforced material and support material (dual extruder).

Level 2. Pedal and HEX_Axle. Separate the parts and print pedal with a strong material. I used Qidi PETG Tough and 10 walls, 60% infill for pedal. Print the axle with a CF-material. The axle has thin sections, and if it is printed standing up - it will likely break due to the FDM layer adhesion weakness. If it is printed lying down, supports will be very difficult to remove at the hex end. Could be solved by using specific support material or other print technology. 

Level 3. Pedal and NO_HEX_Axle. Easier to print than the other levels. Pedal is the same as Level 2. The axle can also be printed without the hex part at the end. Instead it can be assembled with the aluminium rod using glue and a rivet. I had to print the axle at 20 degrees incline with tree supports in order to succeed with the PETG-CF material I used.