Supernova high beam switch adapter for Magura brake lever SupernovaBarrelV1.0

Initial Situation & Development:
The mount for the Supernova high beam switch doesn't provide enough counterpressure to turn the high beam on or off without twisting it.

It was important to me that the adapter be positioned as close to my thumb as possible so that I could easily and quickly find the switch, even in the dark. The original Magura mount seemed most suitable to me, but it's almost impossible to find on the market anymore (if you're thinking that you can print them and there are already 3D models, please read the safety considerations).

So I decided to get myself a 3d-printer and designe one by myself. Main focus was sturdieness and position which left me with the lower srew on the brake itself. I took the meassures oft the flimsy mount and started modelling in FreeCad by adding barrels and subtracting the brake clamp contours. In fact, this is my very first model created for 3d-printing and using CAD …

Amazingly, after just three iterations, I eventually got a working prototype, which could certainly use some fine-tuning, but is perfectly adequate for me. The only problem is that I occasionally accidentally lift the switch out of the adapter, and the magnets fall out. So far, these have always gotten stuck on the screw, so it was possible to put the switch back in its original position even while driving.

This PLA plus prototype is in daily use for the last 2 years (all weather conditions, all year)  and still in decent shape. This is probably why I never realy got back to this model.

Safety Considerations:
Since I don't want to rely on PLA or PETG as a clamp for such an important component as the brake, I decided to create a slightly different adapter. This one is placed on the actual mount like a washer, which provides a significantly better form fit. By supporting the entire model against the actual brake, the pressure when operating the switch is deflected to the underside of the brake mount, preventing the adapter from breaking.

Print Settings & Material:
I used PLA Plus 0.2 layer hight, 100% infill for the print. A total of approximately 6g or 1.7m of filament is required. The switch is held in place by magnets that can be easily inserted from below. I use 3 2x3 neodym magnets.

Possible improvements (I don't have the time right now - feel free to take over):

* Add magnets during printing to prevent them from falling out

* Slightly relocate the upper platform to be even closer to the thumb

* Adjust the tolerances to create more clamping pressure

* Though tempting: I would not recommand removing the barrel being imortant for stability