Top Handle Cover for Sony PMW-500

Replacement part (COVER ASSY HANDLE (TOP)) for the Sony PMW-500 ENG camera. Includes fully functional print-in-place-buttons as well as the sliding button cover.

ENG photographers are a rough bunch, and parts of their cameras eventually break. This top handle piece is among the most commonly replaced.

Cost of OEM part: $63

I altered the design on the inside in order to reduce the need for supports as much as possible. Some are still necessary, however. The included .gcode file has the recommended custom supports. I have also provided a screenshot showing where to add them in PrusaSlicer.

Adding a brim is also advised.

The print-in-place buttons require a slight amount of stretch to work, so I recommend using a filament that sets fairly soft. I used Overture brand ECO-PLA Black.

PRINT SETTINGS:

• Supports required: YES (custom; see above)
• Brim: YES
• Material: PLA (or anything that sets fairly soft)
• Nozzle: 0.4mm
• Layer height: 0.15mm
• Perimeters: 2-3
• Infill: Concentric @ 5% density
• Top fill pattern: Concentric
• Brim width: 2mm

PRINT-IN-PLACE BUTTONS:

The buttons are mainly floating, each sitting on a flat spring at the bottom. I made the springs as thick as I could while remaining flexible enough to work. They are fairly delicate, so take great care when removing support material. 

Once all support material is removed, run a pick or similar tool around the outsides of the buttons to remove any errant filament strands or over-extrusions. Then gently work the buttons up and down to stretch the springs. In the end, the buttons will need about 1-1.5mm of play. The tops of the buttons should sit right at the tops of the holes when at rest (with just enough clearance for the cover), and about in line with the bottom of the beveled edge when fully depressed.

SLIDE-COVER:

The cover needs to be printed separately from the main body of the part. In should fit right on with just a bit of extra resistance the first time. You may need to file the insides of the slots on the cover if you didn't get the cleanest print. Otherwise, there's nothing to it.

INSTALLATION:

Some of the tolerances had to be made fairly tight in order to get a clean print. A small amount of force may be needed to get the part to fit right away. If it just won't go on, try filing down the inside edges a bit, especially near the front end.

The original part has a slight curve to it that cannot be easily replicated on a 3d printer. This replacement version prints flat, but will still fit with a little bending. Once it's screwed down, the difference is imperceptible.

PLA is pretty soft, so don't overtighten the screws! That's exactly how I destroyed one of my prototypes.

Good luck!