Window Switch Rocker

This is a BMW E46 window switch. Possibly compatible with other car models and brands, but you'll have to check it yourself.


<b>FINAL UPDATE: </b>

I thought this would take longer but with the new adjustments the part fits and works perfectly. I'm impressed TBH. I made the hinge holes slightly bigger, reduce the width of the lever by 1mm and also its "thickness" so it will get into the moving part more easily and slide less.

The result is nearly the same than in the last pictures, and it seems to be sturdy enough for the job.

INSTRUCTIONS:

I advise you NOT to print this in PLA. Use ABS, PETG or something similar. Much force goes in the lever and the hinges are likely to break when fitting it into place if made of PLA. I also advise you to print the part on one side, so that the threads run from front to back and viceversa, ie. perpendicular to the imaginary line between the hinges. I believe this way the part will better resist the forces its subjected to.

I used PETG from Rosa 3D (Navy Blue to match my car body color)
Nozzle: 240C
Bed: 70C
100% infill
0.28 layer height (yup that's right)
Initial layers at 8mm/s
using supports, buildplate only and tree

Got a little warping but nothing too bad IMO.

After its fitted into place, it will take a little pushing and pulling before the button works well. I'd advise you to do this with the actual electronic switch off the mount, until it feels loose enough. When you put the electronic switch back inside the mount it will feel great.

Good luck!

NOTE: I'm disappointed with the result on the car as the LED is too dim or the plastic too thick that you can see absolutely no light even using a translucid filament. I might make a version to ease the light through, but that would be a remix.


<b><u>OLDER STUFF:</u></b>

UPDATE: I was finally able to print this in a more resistant material than PLA: PETG. It looks fantastic and I'm uploading those pics but the fit is not good, so I made this a work in progress until I can figure the exact right size and print parameters for this. Apologies for the inconvenience. Oh yeah, PETG is awesome :)

I printed this in PLA, BUT it's just not the right material for the job. All the parts I tried broke almost immediately at the slightest pressure despite using a 100% infill.

See HERE for the printed result: https://youtu.be/rIq7EBYlClY

PLEASE, if you could print this in ABS and try it on an actual mount, I'd appreciate your impressions about how well/bad it fits, if it works smoothly, if it can bear much pushing and pulling at use without noticeable breaking or tearing, etc.

Thank you!

NOTE: The pictures are 2D scans of the original part, as used in the blend file for reference, NOT the printed part.

PS.: Sorry, I forgot to save the cura project file :/ But I printed at 0.12mm without raft (after having leveled properly the bed). And with the top face at the top, to make it look as smooth as possible, despite having to use more supports than up-side-down.

PS2: I didn't bother copying the lever ribs. I know ribs are supposed to add rigidity, but I guess a bolder body would do just the same and they used ribs to save. The bolder lever is supposed to fit regardless. Please let me know if I'm mistaken about any of these. Thanks.

EDIT: I just reuploaded the blend and STL files after having fixed the non-manifold geometry.

Standard FDM printing settings:
- Layer height: 0.2mm
- Infill: 70%
- Supports: As needed