So many 3D printed pieces for my cargo ebike!
In this episode we tackle designing and printed a whole slew of 3D printed parts for the cargo ebike. Most of these will be cosmetic, however there are still a lot of parts that I need to make that will be functional. The first part we make is going to be a way to attach the front bin to the rack that I have fabricated to the bike frame. The issue is that the bin is sitting upright, however the rack follows the angled lines of the fork, so I need a piece that can take up the gap between the upright bin, and the angled rack/grid. By using illustrator to mockup the sketch, I then imported those dimensions into fusion 360 and from them created an angled brick that should bride the gap between these parts.
Of course nothing works the first time when designing in CAD, but I wasn't too far off from my measurements. My main problem was I made the tolerances way too tight for the internal nut that I was going to insert into the brick. It fit very tightly and although it would go in with some persuasion (hammer) I knew I could do it better. I also wanted to adjust a few of the angles because I know I could get them to work a bit better and have a more flush mount. I made another mistake in CAD where I didn't clip out the internal structure as I should have, so those were two more wasted parts, but in the end I had a design that printed great, and everything fit as it should.
Next I wanted to move on to some of the cosmetic sections of the bike that I have dreamed up. This bike was supposed to be a quick n dirty trash build, but it has moved on to a life of its own. I'm not trying to make it look nice, and this is also more practice with designing and 3D printing because a lot of these techniques will be used in larger, more important future builds. I wanted to try and create some louvers that were functional and this was quite complex to design. Fusion 360 has a cool patterning feature but unfortunately I learned the hard way that you can't adjust each individual pattern, so after spending a ton of time making it right, I had to redo it completely. I was able to finally get it all positioned correctly, and I think it does give some much needed texture and interest to an otherwise plain design. I am also happy with using PETG filament as it's quite glossy, with all of the angles and edges I've designed into these cosmetic parts, it really gives it a striking look as all of the different angles have unique reflections of light and I'm very happy with how that came out.
I also needed a way to hold the battery down, right now it's just sitting on the foam but there is nothing preventing it from flopping around so a 3D printed clamp was in order. I also integrated a way to snap the DC-DC converter on top of this clamp and I was able to use the original mounting clips that come on the converter. I've never made anything like this using 3D printed parts, and you have to make it in such a way where there is enough material so that it's strong enough but still flexible, if you make it too strong it will snap, and if you make it too flexible it will probably snap, thankfully PETG is quite flexible. It actually worked and holds the converter in extremely well!
At this point most of the 3D printed parts are done (still have a few to go) and next we can move on to the seat and ultimately paint this beast!
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⛧ \\ Table of Contents: \\ ⛧
00:00 - Front Bin Mounts
06:41 - Side Panels
10:04 - Battery Clamp
11:35 - Front Cleat
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