When I first bought my 3D printer, I wasn't ready to tackle a project of this size and complexity because I was just getting started with 3D printing and needed to brush up on long lost skills - such as 3D modelling.

Automotive switch boxreplacement

As seen from the printing process, the Raft is the bottom layer that is a bit larger then the actual dimensions of the part being laid out on top of it.

Automotiveswitches and Buttons

Starting printing with the Fan ON at the very first layer, simply undoes the effect of the high bed temperature setting. I've had better results with the cooling fan turned on at a much later stage in printing when it reaches a certain vertical height (along the Z-axis)

And obviously, the raw material to print - I used 1.75mm PLA Black and Snow White for my first prototype demonstrated in this IBLE - The printer came with a 0.4mm nozzle on the hot end.

I was planning on doing this for a long time in order to replace the existing switch panel on my 1923 Model T Street Rod as it was put together as an interim arrangement.

ToggleSwitch BoxKit

3D Printing is definitely not easy and is fraught with failures! Just when you think that you've figured it all out, you're hit with new challenges that need to be resolved even before decent progress can become achievable.

So, what's my problem with this arrangement? Subsequent pictures illustrate them better than I describe them here below:

12V ToggleSwitch Box

Bestautomotive switch box

The pictures show the top panel and body with their key measurements - the assembled views were put together to make sure that the top panel and the body would fit correctly once printed.

A 3D printer with a capacity to print a workpiece 6 in x 6 in x 6 in - I use the Printrbot Simple Metal for this very reason:

Automotive switch boxkit

In this application, I decided to retain the raft on the larger body for the simple fact that the weave on the bottom layer would provide additional strength especially because this part has to be mounted on the steering column and tightened.

Customswitchpanel for Car

I may not use these because the horn-button (in the last two pictures) comes with an integrated metal clamp that currently holds the square switch panel in place . I plan to use this clamp to secure the new Switch box to the steering column

In addition to the two main parts, I had printed out a couple of mounting clamps - these were a product of some of my initial practice runs with the 3D printer when I first bought it.

Dimensions-wise, the prints came out well fitted - there was absolutely no work involved in making the top switch panel fit to its body!

With these objectives, I came up with a two-piece design just as most automotive switch panels are but incorporating the following form and function features:

The above steps have not been elaborated here as they're not exactly 3D printing related and therefore reserved for another IBLE

Installing a heated bed doesn't mean printing is going to be a walk in the park! My initial attempts at printing with the heated bed ran into some epic failures as shown in the visuals.