After some discussion on one of the Forums, I thought it might be a great idea to just create a 3D part. The reason is that the original PKD Blaster (aka Worldcon Blaster) has a slide switch which has a white spindle. For months, I was searching for the actual slide switch which I know would now not exist or if it was, it would be very limited and expensive.
The switch in my design has a very thin 1.5mm x 1.5mm black spindle and so, I was thinking, why not just 3D print a while spindle cover for it? And so, after a quick go with the SketchUp, I was ready to export the file as a .stl format and send it off to JLC3DP…
This took about less than 45 minutes on after I realised I already had the STL import feature installed since the last time I opened AndersFP’s 3D files. This design is place over the existing mini switch. I had to make some assumptions that the spindle is 1.65mm x 1.65mm. Sucks that I am not at home to take measurements of the switch. (Update: OK< its actually 1.5mm x 1.5mm)
In theory, the switch can fit into the clip but it will be loose. The free-play is to allow the switch’s spindle to fit in while at an angle (during when the PCB Board is sliding into the Amm clip)
This is roughly how it would look like and I used the SLA Resin LEDO6060 option from JLCPCB, where the resin is naturally white.
Because of the size requirement of 0.5cm x 0.5cm x 1.0cm, I stuck another piece back to back to meet the requirement.
Update [less than 10 minutes later]
JLCPCB reported that my .stl file had error and bad edges…
This image was the only clue I got from them and the errors were, “there are some errors and bad edges detected”…
After chatting with their Agent, I got a much more clearer picture of the issue. However, it is still greek to me. The only clue were the comments on the right.
Looking back at the design, I literally cannot find any mistakes of bad edges.
But once I changed the view mode away from X-Ray, immediately the first error (red) was shown or so I though. (Update: This was not the error)
12:09 Second Feedback
Apparently, this confirms the four square edges are the issue. Maybe I should not put them at a slope?
I am not sure why they showed me this image because the middle whole bar suddenly became solid.
Update: 20240925 The nightmare continues…
After a fitful night of sleep, and in desperation, I had the .stl file repaired using AutoDesk’s Meshmixer. And this is how it looked when I imported it to SketchUp. Just in case you are wondering, I placed two switch covers back to back, only separated by four 0.5mm cubes. This was because JLC3DP’s Ledo6060 resin would not accept any files smaller than 0.5cm x 0.5cm x 1.0cm.
And this X-Ray view is to show you the centre is actually hollow, where you put this over the original switch’s spindle.
Repairing the file in Autodesk’s Meshmixer
Throwing in the towel
After the file was ‘repaired’ via AutoDesk’s Meshmixer, I sent it off only to receive the bad news. It was so bad that after this 6th attempt, they cancelled my order.
Audit failure reason: File errors are detected (broken facets, bad edges and bad contours), which will result in printing failure and damage of the part. These errors occurred because there might be some accuracy algorithms difference of converting different format files between the different software or some hidden surfaces had not been deleted yet when drawing the structural surfaces. Please kindly check and generate a new file to submit again for further check. Thanks !
Update 20240926 NetFabb can’t even help
So, yeah, I tried NetFabb Basic Legacy version (Before it was bought over by AutoDesk) and although it has repaired the file, JLCPCB still returned an Audit Error. Not sure if I am using the Software correctly but, I am going to take a rest now, and do a stock-take of my components to manufacture the Boards first, followed by the LiPo charger and Manual. You’ll need to REGISTER FIRST with NetFabb before you can DOWNLOAD the software. Do be aware, this is the Windows 32-bit version, before AutoDesk took over.
How now, Brown Cow?
Not about to give up, I have a Plan B, which is to ask a friend to check on my file. And, maybe, get another friend to 3D print it as economical as possible (But I doubt it). For the time being, I have to wait for the response…
Where to get what (no, not the Boards and I have not produced them, not even a link to sell them yet):
