3D printed bar inserts?

[faklord]

I’m thinking about printing bar center inserts (for power lines to run through) for carbon bars.
Has anybody been doing this? If so, is it a worthwhile and is there a preferred material?
I’m expecting wear to be an issue, so would make something that is easily replaceable.

[downunder]

And how would you replace the centre insert?

To be fair, buy a SmoothOn PU kit and go wild with a mold. Way more industrial.

And 2 part silicone for a mold. All this about AU$50.

[faklord]

And how would you replace the centre insert?

To be fair, buy a SmoothOn PU kit and go wild with a mold. Way more industrial.

And 2 part silicone for a mold. All this about AU$50.

Do you think a PU part would be hard enough? I realise a printed part wouldn't be very hard but it'll be easy to knock out a few spares. Anyhow, the intention of the post was to find out whether the idea is viable.
I think if I was going the mould route I might try something like graphite loaded epoxy.

It should be reasonably easy to make it replaceable. Something like this - Small hole on rider side.

[downunder]

I think if one is skilled in something it is better to stick to that. However, than no new skill

What is a shore hardness of printed stuff, Epoxy and PU?

Graphite is not great, you'll have it everywhere on hands and rope.

When u bend a bar that insert will not add anything to bending resistance in any axis. There will be a chance that carbon will crack where the bolts are, when is bent. Plus, seeing smaller hole protruding from the insert, that is impossible to place inside the tube.

We need something glued in the middle for 2 axis. It is metal we are replacing, correct?

Metal has resistance in all axis, carbon hasn't. So the best would be Alu cylinder but coz corrosion, it is a no go.

D.

[Jyoder]

After cleaning the inside of the bar with drill-brush and water, I fill the center hole section with epoxy with micro balloons and with 10-20% added graphite powder mixed in and then carefully bore out the hole with a Dremel and sand carefully with paper rolled on a chopstick. So far works well, slides smoothly, and with minimal wear. No graphite dust on hands or line with use.

[faklord]

After cleaning the inside of the bar with drill-brush and water, I fill the center hole section with epoxy with micro balloons and with 10-20% added graphite powder mixed in and then carefully bore out the hole with a Dremel and sand carefully with paper rolled on a chopstick. So far works well, slides smoothly, and with minimal wear. No graphite dust on hands or line with use.

Yes that's another option. Though I think I would print a plug to give the hole the right shape and just give a finishing wet sand (I hate epoxy dust).
Are you running bare dyneema through the bar (rather than PU covered).
and how approx many hours has it been used.

I assume that is 10-20% graphite by weight?

Thanks

[juanpasala]

I’m thinking about printing bar center inserts (for power lines to run through) for carbon bars.
Has anybody been doing this? If so, is it a worthwhile and is there a preferred material?
I’m expecting wear to be an issue, so would make something that is easily replaceable.

It is possible, but It was a pain in the ass to print it, specially with normalstring 3d printers, had to to it with uv resin, but still had a lot of problems gettinit sticking to the plate.

[omg]

Been thinking abt the same thing, however, would just a simple nylon rod inside of the carbon bar work? Then just drill/machine the depower rope hole in the nylon?

[TheJoe]

PETG, ABS, or Nylon would work for printing. PETG is the easiest to print and does not need an enclosure or a vent system since it does not off gas like the other two. You would have to still sand down the inside as it would be rough from the different layers. Hell I would be interested in trying it if you send me the STL file or post it somewhere I can download it.

[faklord]

I can print PLA, PETG, ABS. Have never tried nylon.
Happy to send you the stl.
Have sent you a PM