Cracked/broken plastic

So I got my new boards and connectors and went to take apart my M4 to install them. I saw that the parts holding the arms together on the top and bottom of the arms were both broken. I’m not sure what I did, and I’m SURE there are tons of more hours on most people’s machine than I have run. Has anyone else seen this?


I don’t imagine my 3d printing them would be strong enough especially given I don’t print in tough materials nor will my printer handle it. So I’m ordering more, but I’m not sure what might have caused this…

yep - I have definitely seen this. I reprinted stuff using PETG, still seems OK, I did try PLA and that wasn’t quite good enough

Yes… broken clamp… First only the little bracket thingy. I made one from steel as replacement.

Later the whole upper clamp broke… its a weak spot. I noticed when i was setting z axis and the router just moved out of the maslow.

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I haven’t cracked a clamp yet, but my biggest issue is getting them to exert enough pressure on the router to keep it still. It gets reasonably tight, but, often when I’m tightening a bit down, the router will then turn a bit in the clamp which then throws off the alignment for the spindle lock button.

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Here’s my design for a different clamp wedge - that will not lose the nut if you happen to loosen everything up too much

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This is excellent feedback. I am going to talk to the factory about reducing the glass fiber content in these parts. It seems like they are a little to brittle at the moment.

As I was dis-assembling again, I found some more weak points around only the bearing side.


Also, here is another pic fully disassembled of the clamp parts:

Also, my garage temperature probably has not quite gone below freezing yet, but surely will at some point, and in the summer gets up to ~110F at times. Maybe when not cutting actively, the maslow should come inside to prevent any issues with the plastic?

I also notice the clamp wedges were almost a crumbling texture where they fractured (same on the clamps where they broke), and I wonder if a material more “stretchy” like abs would be better?

Also to be clear I’m not mad about this… just trying to help iterate on it. I know plastic keeps the cost down, but I wonder if other materials might be better suited for some parts that are under stress, even at increased cost.

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