This OSAT Project helps multiple goals, primarily goal 10 by helping to make bike transportation more accessible and to decrease the cost and increase the ability to repair a bike that has a broken axle. This part was designed to replace the original axle on my 2017 Raleigh Tokul 3 mountain bike, but could easily be modified to fit any "Thru" style bike axle.
This part features a hollowed center section to reduce the material used in the print, and otherwise uses a 75% infill for strength. The first iteration used a 50% infill, and due to that and a misplaced thread relief, it was not able to withstand the abuse of being ridden hard. The current model has been ridden and tested thoroughly, and has survived numerous hash riding conditions.
To further increase the durability of this part a higher infill percentage could be used, and to increase the usability a Hex keyway in the threaded end of the shaft would allow for the axle to be properly torqued more easily.
Bill of Materials[edit | edit source]
- 22 Grams of PLA Filament
- Part Files (Which can be found here: [1])
Tools needed[edit | edit source]
- MOST Delta RepRap or similar RepRap 3-D printer
- M12-1.5 Die to cut threads in the end of the shaft
Skills and knowledge needed[edit | edit source]
- 3D printing basics
- How to use a Die to cut threads
Technical Specifications and Assembly Instructions[edit | edit source]
- Axle was printed with PLA with the length of the shaft in the Y direction
- Printed at 215C and a heat gun was used to preheat the bed to reduce warping
- Print Time: 1 Hour 46 Minutes with a 60mm/s print speed
- After print is complete some minor filing/sanding may be required to ensure a tight fit to the hub and bearings
- Use the die to cut threads on the end of the shaft. Do not cut them any farther than you need, as this will reduce the overall strength of the axle
- Torque the axle to the bike manufacturers recommendation (mine was 6 Nm)
Cost savings[edit | edit source]
- Total cost $0.375
- Commercial Equivalent - $32.10 [2]
- $31+ or 98.8% savings
Benefited Internet Communities[edit | edit source]
- Transport
- Sustainability
- Green Living