3D printed lock for Ford NACS adapter

[Sikkun]

And believe that someone knows they can just stop your charge, unplug the adapter and steal it.

If one does get stolen….totally going to be by another EV owner, not some rando.

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[Jeff-NoVA]

PETG is a good filament for this (recognized it immediately)

For a beginner like the other poster, it might be helpful to say that PLA, the most common printer filament type, is not appropriate. PLA sags somewhere above 100F to 110F so not a good choice for functional outdoor use. ABS and ASA would be two other good choices (and some more exotic stuff).

For anyone who doesn't want to buy a printer, there are 3d printing companies and services. You can upload a file to them and they send you the response. If you look up "3d printing service" in a maps application, or on the internet, you'll see a number of them. There might be one near you. This is certainly better than learning how to own and operate your own printer for a small number of parts.

A lot of public libraries also have 3D Printers and will print most anything you want (within reason) for free.

 

[Fretless_5]

Very cool! Would you be willing to share a STEP file? I use Fusion 360 for 3D CAD, so if you do too, we could collaborate on the design.

Another Fusion 360 user here too.

 

[worachj]

A lot of public libraries also have 3D Printers and will print most anything you want (within reason) for free.

Thanks, never knew libraries had 3D printers for public use! Checked out my local library and they have one.

"Use our Ultimaker 2+ Connect printers to print your 3D models. PLA filament provided."

Don't know anything about 3D printing. Need to do some research!

 

[Jeff-NoVA]

Thanks, never knew libraries had 3D printers for public use! Checked out my local library and they have one.



Don't know anything about 3D printing. Need to do some research!

The question is whether your library offers PETG or ABS filament options. You don't want to print anything for use in a car with PLA as it will melt.

 

[bbulkow]

The question is whether your library offers PETG or ABS filament options. You don't want to print anything for use in a car with PLA as it will melt.

Buying your own spool costs about $20 bucks and will be enough for a few adapters (guessing based on side and experience). Spools are easily available on Amazon. I like eSUN for PLA but polymaker is well regarded and amazon basics is not terrible usually. Assuming the libraries have slicing profiles for those filament types - PETG and ABS are *fairly* common. Both ABS and PETG are finickier than PLA which is why PLA would be standard at a library. You also have to learn how to load filament on their model of printer but probably if they allow you to, there's someone to help you (sometimes) or an easy to follow instruction guide. A larger functional print like this, in PETG, is probably a few hours at least. They could also ban some filaments - different filaments outgas different chemicals as they print. PLA is considered non-toxic, others, not as much. Pros have ventilation, libraries may not be able to retrofit (and are public spaces).

Here are the names of a few well regarded internet services. Upload your model, wait for Shipping.

Protolabs, Shapeways, JLC3DP

A google search also returns Xometry and Craftcloud which I haven't heard of.

UPS store claims a few locations with 3d printers too. https://www.theupsstore.com/print/3d-printing

Plenty of urban areas have little mom n pop 3d print services. Search google maps.

Unless you're keen on it, best to order from a service. Getting parameters right requires a lot of trial and error. We all hoped it would be just print and have the thing, but turns out it's more than that. Services for the win.

 

[bbulkow]

it's only worth addressing if one drives the Mach E long distances and frequently (I do - now just under 75K miles on mine), and DC Fast charges during those trips, and gets out of the car and walks about during charging (I always do, for my health and to get my butt circulation moving, and the dog when she's with me needs movement as well).

And you believe someone would steal it. My view is it's terribly unlikely. All the charging locations I've been at feel pretty safe. No tesla owner needs it, rivian and ford owners who pull in probably have their own, the culture of not touching someone else's charging cable is a strong deterrent. I'm always more worried about someone smashing the car window, and if I feel it's a sketch location from that perspective, I stay with the car.

But reasonable people can differ.

 

[Sikkun]

PETG isn’t too different from PLA to print, especially nicer PETG. I generally swap between the two and don’t do anything different (outside different profiles).

I will say if someone wants their own printer, there is a lot of advantages to spending more
on a Prusa or Bamboo instead of the cheaper Ender and other clones.

Not that you can’t make them work, but have met a lot of people who spend way more time tinkering with their cheap printer, instead of printing.

 

[21st Century Pony]

And you believe someone would steal it. My view is it's terribly unlikely. All the charging locations I've been at feel pretty safe. No tesla owner needs it, rivian and ford owners who pull in probably have their own, the culture of not touching someone else's charging cable is a strong deterrent. I'm always more worried about someone smashing the car window, and if I feel it's a sketch location from that perspective, I stay with the car.

But reasonable people can differ.

I don't know whether anyone would steal it yet there is a chance they would, maybe for hoped-for profit or just for impulsive curiosity.

In a related Tesla adapter locking thread I mentioned I had been a teenager in my past, and impulsiveness certainly had shown its ugly head in that part of my life. Not to mention some of my friends, who were a bit less savory than I was at that time. I'm sure I am the only such former preteen / teen miscreant on this forum... willing to admit it anyway

And then there's the occasional drunk trying to make a buck for the next fifth... not that uncommon although they try to not attract attention.

The point is not to protect against everything that might happen, rather to lessen the small but certainly existent chance that on a long trip I (we?) find ourselves suddenly deprived of a majority of DC Fast charging points as an unplanned and unwelcome development.

Stealing a small Tesla adapter is much less attributable than smashing a car window, which by clear evidence is a crime scene with higher risks for the perpetrator (noise, security cameras in the area, factual evidence etc.). Taking a Tesla adapter seems more of a "he said, she said" scenario if it were even observed by a third party.

 

[ocdxfv]

No problem sharing. I'll send you a direct message. This is a work in progress and I'm open to any suggestions or other people finding solutions. I already have a few other ideas to try.

As for the non-locking side, I printed this with 4-5 mm walls in PETG plastic. It's very rigid. A hammer or crowbar could break it. But the point is to prevent someone from just disconnecting it and walking away.

When you get a version you like, could you send me the file? I am supposed to get my Ford adapter this month. In the meantime I’ve been using an A2Z adapter and have been using a much less elegant solution for securing it. Yours looks quite nice.

 

[JustBob]

When you get a version you like, could you send me the file? I am supposed to get my Ford adapter this month. In the meantime I’ve been using an A2Z adapter and have been using a much less elegant solution for securing it. Yours looks quite nice.

I'll post it to thingiverse when I get a chance.

 

[ipca204]

And then there's the occasional drunk trying to make a buck for the next fifth... not that uncommon although they try to not attract attention.

WOW...you are really reaching with that scenario...lol...

 

[21st Century Pony]

WOW...you are really reaching with that scenario...lol...

I had some real-life experiences with a similar scenario. So no I'm not.

 

[Mwill]

Here's my first attempt at 3D printing a lock for the adapter to prevent someone from just disconnecting the adapter and taking it while charging. It has 2 parts (plus a padlock). The inner sleeve that covers the release button is tapered to match the size/shape of the adapter. It has to be pushed on from the back side. I believe it's tight enough and strong enough so that it can't be pulled off the front of the adapter. Then the second piece slides up from the bottom to keep the sleeve from being pushed back. Lock together with a padlock.

I'm open to suggestions. This design does not prevent the locking lever from moving, but just prevents access to the release button. I don't believe you can pull the lever up when installed without some sort of hooked tool. Also, I left the release for the NACS plug exposed. That could be covered up as well, but thought it best to have a way to quickly unplug. I did consider some sort of hidden button lock (like a puzzle box), but thought that could be figured out. I plan to print this in black to conceal it somewhat when in use.

Do you have an account on Printables that you could share this model on?

 

[DevSecOps]

I have commercial grade 3D printers. If someone was interested in this made with commercial grade materials, either PA (Nylon), PA-CF (Nylon/Carbon Fiber), CF (Carbon Fiber) or PC (Polycarbonate), I'd be willing to print some.

I concur with others that if you have a Fusion3D file that would be amazing.

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