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  1. AEtherScythe

    Charge Port Cover Dent Prevention – 3D Printed DIY Solution

    Quality looks good. IIRC, your friend has the same printer as mine. If he is printing the TPU directly on glass he may from time to time experience some bed adhesion problems at the skinny end that is the actual wedge. I uploaded a version with an in-built partial brim, which solves the...
  2. AEtherScythe

    Charge Port Cover Dent Prevention – 3D Printed DIY Solution

    Shapeways got back to me about hosting this in their "shop" and they can't do it with TPU yet and didn't offer any hints as to whether/when they'd be working on it. It means if you want a high quality part via SLS process, you'll have to manually upload it and place an order. The other service...
  3. AEtherScythe

    Charge Port Cover Dent Prevention – 3D Printed DIY Solution

    One of the benefits of living in greater Detroit is there are top-notch guys around who do this kind of work for the auto shows and such. Jeremy Kraft has been working on MME's for a year by now, having done work for Ford related to MME promotional events. We couldn't be more pleased with his...
  4. AEtherScythe

    Charge Port Cover Dent Prevention – 3D Printed DIY Solution

    My samples from Shapeways arrived today. The quality is very good. Way better than I can print via extrusion from TPU filament. These are unfinished, as in the surface is a bit powdery still, but it's unimportant for the purpose. Shapeways only offers TPU in the natural/white color you see...
  5. AEtherScythe

    Charge Port Cover Dent Prevention – 3D Printed DIY Solution

    I've uploaded the V.1B.S version of the part, which has an in-built partial brim. I find this version to print more reliably w.r.t. bed adhesion. Essentially it has an added amount of material around the skinny end of the part, which is connected via three small spans. It's faster printing...
  6. AEtherScythe

    Charge Port Cover Dent Prevention – 3D Printed DIY Solution

    The before... The after... Here in Southeast Michigan if you need your dent removed, call Jeremy Kraft at Dent Krafters Inc. 313-806-1953 He does GREAT work!!!
  7. AEtherScythe

    Charge Port Cover Dent Prevention – 3D Printed DIY Solution

    As far as my expectation, any of these nice people offering to print these are not looking to turn a profit, but merely to recoup costs. And that's fine. The part is posted with a proviso that it's there for non-commercial use. The most straightforward approach under the non-commercial use...
  8. AEtherScythe

    Charge Port Cover Dent Prevention – 3D Printed DIY Solution

    In case you were wondering what it looks like to print it at home in TPU flexible filament. =D In reality it takes 2 hours and 20 minutes per part on a Lulzbot TAZ Pro with 2.85mm PolyMaker PolyFlex 95A TPU, shown here.
  9. AEtherScythe

    Charge Port Cover Dent Prevention – 3D Printed DIY Solution

    Yes, they're a very good provider and my samples are on the way already. But Shapeways are also double the cost of another provider who I'll mention if things work out with them.
  10. AEtherScythe

    Charge Port Cover Dent Prevention – 3D Printed DIY Solution

    As you learned, PLA is not flexible. Without the retaining tabs, you're liable to "lose" the part inside and get it stuck in such a way that it would be very hard to get out and regain function of the door.
  11. AEtherScythe

    Charge Port Cover Dent Prevention – 3D Printed DIY Solution

    Yes, I intend to update the thread after I've received the samples, e.g. if the samples are good, I'll post a link and provide instructions for what to specify In the order. Actually, I'm hoping for one better. I approached the one provider about having the part hosted on their site so you...
  12. AEtherScythe

    Charge Port Cover Dent Prevention – 3D Printed DIY Solution

    I already said I have a day job and this is not my money maker opportunity. I offer what I did as is. Take advantage to your advantage or not. Up to you.
  13. AEtherScythe

    Charge Port Cover Dent Prevention – 3D Printed DIY Solution

    Here you go... Here's a jug of a mostly-clear, somewhat amber liquid. You may not know what it is, but please let me advise you to keep your matches away. ;-)
  14. AEtherScythe

    Charge Port Cover Dent Prevention – 3D Printed DIY Solution

    I'll update folks on how things go with the two printing services through which I've ordered samples. You can download the part and upload them to the service of your choice or try to find someone who can print in flexible materials (and your mileage will definitely vary if you go that route)...
  15. AEtherScythe

    Charge Port Cover Dent Prevention – 3D Printed DIY Solution

    I repeat. I have the same detent and yet we have a dent. We definitely did not even bump it. Thinking it was the high-winds when we were at a DC fast charger. :-((((( That detent is far from adequate.
  16. AEtherScythe

    Charge Port Cover Dent Prevention – 3D Printed DIY Solution

    I've posted two versions of the part, one without support so you can send off to a service to have it printed in TPU 85A (or similar) using Selective Laser Sintering technology or if you have a direct drive printer you can try using your slicer's built-in support with that version (V.1.N). The...
  17. AEtherScythe

    Charge Port Cover Dent Prevention – 3D Printed DIY Solution

    Just a bit of an update on why I haven't yet posted the STL file anywhere. I've had my printer running all day trying to get a better result on the in-built support. So far not great. I'm still having to take a razor knife to separate the in-built support form the part. I can't see that...
  18. AEtherScythe

    Charge Port Cover Dent Prevention – 3D Printed DIY Solution

    I have this same detent. I even tried to use it in an earlier prototype to keep the wedge in place. That detent is in no way in contact with the charge port door arm. It serves no useful purpose that I can see.


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