Flexible Handle Grip for Sony PMW-500

Replacement part (GRIP FOR CAMCORDER) for the Sony PMW-500 ENG camera. Printed using flexible filament.

ENG photographers are a rough bunch, and parts of their cameras eventually break. The different handle components are a pretty common casualty. Unfortunately, photographers also tend to make things worse by “fixing” it themselves using gaffer tape. The residue from the tape is what typically destroys this particular part.

Cost of OEM part: $43

The grooves are aesthetically changed, and there's a slight difference in the hand contours. Otherwise, this is virtually identical to the original part, if maybe just a tad stiffer due to the particular material I used.

There are two different ways you can go about printing this. In my opinion, the first method outlined below is by far the easiest. You be the judge.

INSTRUCTIONS (TWO PIECES):

I strongly suggest printing this in two separate halves. The complete model is included for reference.

Print each half (individual .stl files provided) with its larger end as the base. They're short enough that they'll remain stable as long as your Z level is properly calibrated. If you're still concerned, add a brim with a fairly tight separation gap. You'll need to remove it later, but that may be a small trade-off. Up to you.

You'll need to super glue the halves together. If you haven't glued FLEX before, do a test first with whatever glue you plan to use. My go-to is Loctite Professional Liquid (not the gel), and it works great on my brand of TPU (Overture). Be warned that due to the smoothness of the material, the right kind of super glue will set near-instantly. There will be no chance for adjusting, so get it lined up right the first time.

      PRINT SETTINGS (TWO PIECES):

• Supports required: NO
• Brim required: NO, but recommended
• Nozzle: 0.4mm
• Layer height & first layer height: 0.16mm
• Perimeters: 2
• Top & bottom solid layers: 5-6
• Infill: Concentric @ 100% density
• Top fill pattern: Concentric

      FLEX RECOMMENDATIONS (Overture brand Black TPU):

• Avoid crossing perimeters: Enabled
• Seam position: Nearest
• Perimeter speed: 30mm/s
• Infill speed: 45mm/s
• Retraction Length: 0

Good luck!

INSTRUCTIONS (SINGLE PIECE):

Proceed with caution. NOT FOR BEGINNERS.

Printing this as one complete part is possible, but not for the faint of heart. I can only recommend trying this if both you and your printer are very comfortable working with FLEX.

Just as with the method described above, the model will need to be sliced standing upright, on the larger end. Printing this flat is utterly impractical with FLEX due to the amount of supports that would be required (the inside surface needs to fit the camera handle precisely, so altering the model to eliminate supports isn't an option). Frankly, I'm not even sure it's possible to print this flat as one piece, and I'm not willing to find out.

In the proper orientation, the part is 137mm tall, making stability a major concern a little after the halfway point. To help with this somewhat, I recommend using the same settings as outlined above, with the following changes.

      PRINT SETTINGS (SINGLE PIECE):

• Brim required: YES
  Width: 3-5mm
  Separation gap: 0.04mm
• Perimeter speed: 25mm/s
• Infill speed: 35mm/s
• Travel speed: 100mm/s

Making the brim that close effectively merges it with the bottom layer. This may be essential if you don't want it to release from the bed. You'll have to cut the brim off, but that's not a huge deal. Reducing the speed helps minimize the amount of wobble as the print nears the top. This is FLEX, though, so it will wobble the higher it gets. 

At least, it would have been. I walked away for just a few minutes. With less than 10% remaining, the filament slipped off the reel and got snagged, causing the print to fail. Had my setup been better laid out to accommodate taller prints, I'm confident it would have succeeded to the end.

You may not have these issues if your printer is fancier than mine (Prusa MINI+), but I've got what I've got and make the best of it. Things still work out more often than not. This was just not one of those times.

Good luck!
you're gonna need it…