Over Engineered Light Switch Cover

This is a Light Switch cover for a USA rocker style light switch. It uses a rack and pinion driven by a turned knob. It is nearly fully 3D printed aside from 3 small bearings which are cheap on amazon, it is easy to assemble and disassemble as well as install. It works by turning then rotational motion of the know and converting it to linear movement via a rack and pinion which acts on the rocker switch. The text in the top cover can be printed in with a multi color printer or the bodies of the text can be removed on a single color printer and it will simply engrave the text.

Most can be printed with two walls and 15% infill, I recommend raising infill to 25 percent and 4 walls on the rack and the bottom cover.

tree supports are helpful on the bottom cover, required on the pinion gear and a brim is recommended for the switch bearing axle. 

PLA is plenty strong.

Requires three 3mm ID x 8mm OD x 4mm wide Bearings which can be purchased from amazon.

I have provided screen shots of printing orientation/supports/brim from the slicer. 

Assembly instructions(Outlined in pictures): 

1) Press bearings into the top and bottom cover plates(This can be done by setting them on a flat surface and pressing with a metal object or screwdriver.

2) Insert the Switch bearing axle into one side of the rack.

3) Line up the 3rd bearing and press the axle through it and center it on the other side of the rack to retain the bearing.

4) Place the rack onto the bottom cover plate over the pins with the rack gears facing the side with the bearings.

5) Place the pinion gear into the bearing of the lower cover plate with the longer portion of its axle shaft facing upwards.

6) align the upper cover plate posts with the lower cover plate posts. Insure the upper pinion gear axle is aligned with the bearing in the upper bearing plate.

7) Press the upper cover plate down until the corner retainers slide over and hold it down.

8) Press the knob onto the pinion gear axle shaft.

9) Assembly is Complete! You can now install it over your rocker light switch, if it is difficult to install the mounts screws you can assemble the plate on the wall! Assuming your light switch is installed correctly, rotating the knob to the Left will turn the lights on and to the Right will turn the lights off.