KTM 640 Adventure (2007) Tail Light Lens

This is a replacement tail light lens designed for the KTM 640 Adventure (2007). The model is intended for FDM 3D printing and replicates the original shape while allowing for easy installation.

To achieve better light diffusion and visual appearance, an internal texture was applied using a knurling pattern.

Material

• Red translucent PETG (recommended for proper light transmission, durability, and heat resistance)

Printing Settings

Layer Settings

• Layer height: 0.22 mm

• First layer height: 0.22 mm

Extrusion Width

• Default: 0.45 mm

• First layer: 0.55 mm

• External perimeter: 0.45 mm

• Internal perimeter: 0.50 mm

Walls & Infill

• Perimeters: 1000 (ensures fully solid part)

• Top solid layers: 5

• Bottom solid layers: 3

• Infill density: 100%

Seam & Surface

• Seam position: Random

• Inner seam offset: Enabled

• Seam gap: 50%

• Smoothing (ironing): All top surfaces

Supports

• Tree supports were used for better surface quality and easier removal

Orientation

• Based on testing, the best results were achieved when printing the model flat on the build plate, without any tilt

Speed

• First layer: 25 mm/s

• First layer infill: 50 mm/s

• External perimeter: 25 mm/s

• Internal perimeters: 25 mm/s

• Small perimeters: 40%

• Infill / solid infill / top surface / gap fill: 25 mm/s

• Travel speed: 200 mm/s

Acceleration

• Default: 4000 mm/s²

• External perimeter: 1500 mm/s²

• Internal perimeters: 1500 mm/s²

• Bridges: 40%

• Infill: 50%

Additional Notes

• Internal texture (knurling) was applied using bump mapping to improve light diffusion.

• For better color saturation, a red LED bulb (P21/5W BAY15D) is recommended.

• The lens was mounted using transparent silicone adhesive (Kerry KR-145-0).