Knaus SkyWave 650 MEG - Bed ladder mount bracket

Bed ladder mount bracket for removable ladder to the beds on the back of a Knaus SkyWave 650 MEG Camper and probably many more as it's a standard part for mounting a removable ladder and it's prone to break.

It's a replica of the original bracket and it's clear why the design breaks easily at the main two weak spots as the wall between the horizontal bar (where the ladder hooks on) and the side is only 1 mm in the middle and 2 mm on the sides as the screw holes are placed very badly.

A future improvement would be to find a different way of mounting it but for now it's a replica to fit the existing holes.

I printed it in PETG with 0.20mm width but variable layer height down to 0.07mm for the part with the horizontal bar and I used 40% infill with Rectilinear fill pattern and 5 perimeters.

I will update after some time if it breaks again or holds strong enough for normal usage. 

Usage update #1: As suspected after some usage it did break at the same weak spots. A redesign is in progress to remove the weak spot without having to drill new holes, the current idea is to reverse the screw and make a slot on the side for the M4 nut and screw it in from the back, with that the top screw hole can be avoided and closed which means no thin wall at this point which should result in a stronger part which is needed when the whole ladder get's pulled out of the bed storage compartment.

Update #2: I Reprinted it on the side with correct orientation for strength in the right direction. For a second durability test using 0.1mm layer height and have it on the side when printing (added organic support).

Update #3: Had to widen the holes (which also makes the wall even thinner as the screws head is a tiny bit too wide. Created it as V2 (depends on the accuracy of your printer if needed or not)

Note: The FreeCAD design file (and the resulting STL) show a 0.01mm layer partly going into the hole, this will be gone when slicing. I need to figure out how to make the pocket properly on a curved surface and this is the first design in FreeCAD to learn how it works)