Stackable Lego Gauge Train Track/ High incline wall railway

UPDATE: currently finished the project these tracks were used for  vid here  on my yt channel  check printables comments for updates 

Another UPDATE:  modular bridges are now supported, take a look in the onshape link to download them,  they are meant to be soldered/ plastic welded together.

this video shows model 1   model 2 is significantly quieter but can't carry very heavy loads

most of the technical engineering of this project went into making the trains suitable to climb the high inclines in my layout

currently uses a highly modified lego train with rubber wheels to climb the 14 degree inclines

Update: video got deleted with my yt dont know when it will be up again

can post more on train if people are interested it took more time to develop a working train than it did the whole layout

currently its a very long write up ( still very interesting with lots of physics)

dm me if you want to see that  probably pretty useful for anyone going beyond 5 degree inclines 

i check my dm at least once a month/ email notification ( this turned out to be a lie more like once a year) 

ANYWAYS  back to the tracks 

Currently, straight track, curves (52 stud radius) and elevation have been modeled cad file/ links+ instructions  included on how to modify* 

also a cool bracket for mounting to walls is included, attach tracks with 3m double sided tape if needed to the wall  ( not my design I just resized it original is on printable somewhere under generative design that I cannot find).

TLDR

Model Trains is an expensive hobby.   I had some lego city trains and wanted a ton more track to play with.   Upsized and modified os railway track to Lego L gauge and then created custom supports in prusa slicer so that they print on top of each other.  Costs under 25 cents per 200mm.     

on an ender 3 you can print 80 tracks in 1 go

Instructions

DOWNLOAD from onshape  the step file is probably outdated by the time you read this 

The stacking is a tradeoff, you dont have to que a print job every 4 hours but you do waste around 5g of supports per rail and 1-2 mins of support clean up time, use an exacto knife , pliers and a deburring tool for best results 

On an ender 3 bed you could theoretically print 80 at a time  for a 5 day print that results in 16 meters of rail !    quite impressive!

not backwards compatible with lego track

Slicing   (VERY IMPORTANT) 

use 3 perimeters to make sure there is no gap fill on top layer 

5-10 percent infil 

similar to stacking face masks (watch this)

I used + 12mm for every stack upwards

 also when in that menu  scroll down to support blocker and click load   then  select part 2 to prevent supports on rail surface.

then enable supports everywhere 

Support type  snug 

xy separation  100 percent to make sure none of it touches connectors 

other than that pretty standard 

use pliers to remove support 

and optionally a deburring tool or exacto to clean up connectors 

this is overall a stress test print   with high tolerances and good cooling/ bed adhession required

I used a soldering iron to weld the tracks together/ to the brackets and then stuck the brackets on with 3m scotch mounting tape ( big roll from amazon) to create the wall track

https://www.target.com/p/scotch-create-double-sided-foam-mounting-tape/-/A-14786672?ref=tgt_adv_xsf&AFID=google&CPNG=Seasonal&adgroup=81-22

Modifying

use onshape to either download the step file or modify via onshape 

I recommend you split the track body with a plane 0.001 from the end connectors so you can then sweep the rail profile with a sketch and then reattach the other end with a transform and Boolean.   (if enough people need a example I might upload a video of this)

This is how you can create custom bends

If too tight a fit  increase the chamfer on the connector prong from 1mm (standard) to something higher in 0.2 increments.    1mm worked with me for a printer with 0.3mm tolerances 

https://cad.onshape.com/documents/aa9c8a6bf970719d8923bede/w/f39510dd42942fd205100565/e/a1e82bb1b65dabea710feabb?renderMode=0&uiState=63db03dafb97c84ceb85ed09

Ps did not initially create the cad for this design used a remix of openrailway that had a step file included, that I cannot find a link back to.