Spray Extender Applicator

Project Description:

I'm presenting a practical Spray Extender Applicator that I designed and created to facilitate work in paint shops, garages, and anywhere a spray can needs to be used in hard-to-reach or elevated areas. Whether for protective coatings, primers, or detailed spraying, this attachment significantly enhances safety, efficiency, and work quality.

Why I created it:

In my work at an bus paint shop, spraying the central light channel under the vehicle roofs was a common challenge. Using step stools was time-consuming, unsafe, and led to suboptimal spray quality due to poor reach. I decided to design a solution that eliminates the need for step stools, speeds up work, saves material, and ensures precise application.

How it works:

The applicator is a modular system consisting of several 3D-printed parts, an aluminum extension tube, and a simple Bowden cable mechanism.

Upper Holder: Securely and stably holds a standard spray can.

Extension Pole: A lightweight aluminum tube (standardly 1 meter long) serves as the extension.

Lower Trigger: An ergonomic handle with a trigger, connected to the upper mechanism.

Bowden Cable: A bicycle-style cable transmits the squeeze from the lower trigger to the mechanism that activates the spray can's nozzle in the upper holder.

Key Features and Benefits:

Increased Safety: Eliminates the need for step stools and minimizes the risk of falls when working at heights.

Higher Efficiency: Speeds up the spraying process – no more handling step stools, allowing for continuous work.

Better Spray Quality: Enables holding the spray can at an ideal distance from the surface, leading to more even and higher-quality coverage.

Material Savings: Due to the optimal distance, paint is not unnecessarily dispersed into the air, reducing spray can consumption.

Easy Assembly: Designed for straightforward assembly with commonly available components.

Materials and Printing:

Recommended Filament: PET-G (for high mechanical resistance and durability, chemical, and UV resistance).

3D Printed Parts: Lower trigger, upper spray can holder, and cable clamps.

Non-Printed Components:

Aluminum tube (length as needed, standardly 1 meter).

Bowden cable + inner wire from a bicycle (approx. 1.1 - 1.2 meters in length, depending on the tube length).

M5 and M6 screws and nuts (for attaching parts to the tube and connecting them).

Print Settings:

Infill: Recommended 20-30% for sufficient strength.

Perimeters: Minimum 3-4 for robustness.

Supports: Are already pre-set in the attached 3MF file.

Assembly:

Print all necessary parts (or load the 3MF file with pre-set parameters).

Prepare the aluminum tube, Bowden cable, and screws with nuts.

Attach the upper spray can holder and the lower handle to the tube using screws and nuts.

Thread the inner wire through the Bowden cable and connect the trigger mechanism to the spray can holder. Adjust cable and Bowden housing length as needed.

This improvement is a great project for anyone looking to leverage the potential of 3D printing to solve practical problems and streamline their workflow. I welcome your comments, photos of your prints, and any suggestions for improvements!