Summary

This is a set of 4 pieces used to create a structural corner for 40mm square alu. tubing.

2 pieces fit together to create x,y,z corner receptor.
1 vertical piece receives two tubes at diagonal.
1 piece receives one tube at diagonal. (Print 2 of these.)

You can edit the parts for different size square tubing.

Use at your own risk. Not designed for taking loads.

Print Settings

Printer Brand:

Creality

                                            <p class="detail-setting printer"><strong>Printer: </strong>                     <div><p>Ender-3 v2</p></div></p>                                                                                <p class="detail-setting rafts"><strong>Rafts: </strong>                     <div><p>Yes</p></div></p>                                                                                <p class="detail-setting supports"><strong>Supports: </strong>                     <div><p>Yes</p></div></p>                                                                                <p class="detail-setting resolution"><strong>Resolution: </strong>                     <div><p>0.2mm</p></div></p>                                                                                <p class="detail-setting infill"><strong>Infill: </strong>                     <div><p>50%</p></div></p>                                                    <strong>Filament:</strong> eSun ABS+                Blue                    <br>                        <p class="detail-setting notes"><strong>Notes: </strong>                    </p><div><p>There are 3 parts to this design:</p><ol><li>The two pieces to create the corner x,y,z fitting.</li><li>The piece on the upright to receive two diagonal tubes.</li><li>The pieces (print x 2) that recieve diagonal tubes.</li></ol></div>

Post-Printing

Extracting support material is best done when the parts are warm.

            <div><p>There are holes to allow for 4mm dia. bolts- No nut required. You can mark off where you want to position the bracket piece on the tubing, then drill a 4mm hole. I used a router as drill bits don't go through the aluminium tube. I broke a drill bit trying.</p><p>If you manage to drill an approx 4mm hole, a bolt will screw in easily, but I didn't need screws for my own purposes which was to build a cage for a hen-run.</p><p>The photo below shows the two part x,y,z corner piece.<br>Both parts need to be printed on the flat for strength purposes- hence the reason for two pieces.</p><p>You can shave the male part of the vertical segment with a box cutter for a snug fit.<br>I'll add more photos when I can. The parts are all working very well- Even better than I expected.</p></div>                    <p class="detail-caption"><strong>Not beautiful but it works nicely. </strong></p>            <p class="detail-image"><img src="https://cdn.thingiverse.com/assets/a5/b8/c5/9d/69/Corner_Bracket.jpg"></p>

How I Designed This

Painful trial and error, and a lot of wasted plastic- But delighted with the end result which works very well.

Structural Bracket for 40mm x 40mm / 2mm Aluminium Square Tubes