3D Printed Window Regulator Clip

[jac]

So I ordered a few clips last time I had to fix the window regulator, which was for one of the front windows. Now one of the rears broke but the clips seem to be different between the front and back. So I figured, I am gonna create my own model for the rear clip, 3d print it and let's see how long it lasts...

Find it here: https://www.prusaprinters.org/prints...ip-51357011680

[Purplefade]

Print that sucker out of something bomb proof so that you don't have to get back in there again - great idea, as long as it's better than the original.

[bnfaustin]

Originally Posted by jac

So I ordered a few clips last time I had to fix the window regulator, which was for one of the front windows. Now one of the rears broke but the clips seem to be different between the front and back. So I figured, I am gonna create my own model for the rear clip, 3d print it and let's see how long it lasts...

Find it here: https://www.prusaprinters.org/prints...ip-51357011680

I love the design and idea of 3D printing the clip. After watching a YouTube video, I simply went the route of:
- Buying a set of license plate holder screws (with the plastic square backer),
- Breaking off any remaining “nut holding” tabs on the old clip, and
- Replacing the all metal OEM bolt/nut with the license plate version.
It will press fit the old clip into place and go through the hole in the window and lock in using the plastic square nut. $1.25 for a pack of 4 at your auto store did the job when I replaced the regulators on 2 of my windows.


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[E53Envyy]

Originally Posted by jac

So I ordered a few clips last time I had to fix the window regulator, which was for one of the front windows. Now one of the rears broke but the clips seem to be different between the front and back. So I figured, I am gonna create my own model for the rear clip, 3d print it and let's see how long it lasts...

Find it here: https://www.prusaprinters.org/prints...ip-51357011680

Looks like a difficult part to print!

Due to the sharp right angles I can see multiple stress points, proper layer adhesion is critical (is it possible add a slight chamfer to reduce stress?).

I'd recommend nylon PA12 for the print as you'll have strength and flexibility. Next would be polycarbonate and I wouldn't attempt PLA or ABS.

Cheers

[Henn28]

Thank you! I have no doubt you can engineer something more robust and suitable than the brilliant German engineering solution that is the window regulator and clip system used in these cars.

[jac]

Originally Posted by E53Envyy

Looks like a difficult part to print!

Due to the sharp right angles I can see multiple stress points, proper layer adhesion is critical (is it possible add a slight chamfer to reduce stress?).

I'd recommend nylon PA12 for the print as you'll have strength and flexibility. Next would be polycarbonate and I wouldn't attempt PLA or ABS.

Cheers

Printing it was not difficult at all. I posted the instructions along with the model.

I do agree that the stress points are a HUGE factor for this particular part. I plan on reporting how long it lasts given that (a) I did not spend more than a few minutes thinking about the stress and (B) I printed it on PETG. So, it is more of an experiment at this time. I am thinking it will last 6 months at most?

I agree on your material choices. I was simply too lazy to switch out to another filament. I am also curious to know if when the part breaks, it causes the carrier to also break and mangle all the wires that move it, because every time that I have had this problem I have had to replace the clip (broken) and the entire window regulator (wires mangled).

[jac]

Originally Posted by Henn28

Thank you! I have no doubt you can engineer something more robust and suitable than the brilliant German engineering solution that is the window regulator and clip system used in these cars.

Lol... I am sure a better mechanism can be devised. But I would not claim to be the one that will do it! I really was just trying to get the window working again and the simplest approach was to copy the original design.

Now, when this thing breaks agains (it will!!!) then I will pause and try to figure out an alternative. But I am not a mechanical engineer, so not sure how successful that will be. But I can always try! Lol

[jac]

Originally Posted by bnfaustin

I love the design and idea of 3D printing the clip. After watching a YouTube video, I simply went the route of:
- Buying a set of license plate holder screws (with the plastic square backer),
- Breaking off any remaining “nut holding” tabs on the old clip, and
- Replacing the all metal OEM bolt/nut with the license plate version.
It will press fit the old clip into place and go through the hole in the window and lock in using the plastic square nut. $1.25 for a pack of 4 at your auto store did the job when I replaced the regulators on 2 of my windows.


Sent from my iPad using Tapatalk

Please do share the video you found on YouTube that uses the license plate holder screws! I assume it was in the video you found... If that's a better approach I will probably just do that the next time this thing breaks! :-)

[jac]

Originally Posted by Purplefade

Print that sucker out of something bomb proof so that you don't have to get back in there again - great idea, as long as it's better than the original.

Hahaha... Yeah, those were my thoughts exactly as I was printing the thing.

[bnfaustin]

Originally Posted by jac

Please do share the video you found on YouTube that uses the license plate holder screws! I assume it was in the video you found... If that's a better approach I will probably just do that the next time this thing breaks! :-)

[mention]jac [/mention]Here is the link to the video showing the $2 fix for the window clip replacement with off the shelf plastic license plate holder screws: https://youtu.be/JwFFd7OJGaI