I just ordered a 12' tall lighting stand for stage/DJ lights. one of the pipe clamps was smashed to pieces when it arrived, and so I thought "this is a job for a 3d printer!!"

version 2 update: So I printed out a copy of my original design, and discovered that after a 3 hour print, my pipe dimensions are actually:

1.625" for the bottom tube, then 1.5" inside that tube. This is really important because my original design just had 1.5" for both sections. Whoops.

version 3 update: Version 2 snapped after oh-so-moderate tightening. :-\ so I've changed strategies a bit so that I can print this thing in a different orientation. I also moved one of the ends of the clamp to the outer edge so that there's a nice flat side for your thumbscrew or knob or whatever. There's really no reason to have to do all the work in the middle.

I've added single-filament-wide walls in a couple of places to support the extreme overhang areas. Snap those off after the print is done.

So, here we go again. This is so much faster than ordering a replacement part? It's cheaper than a mechanical engineering degree, certainly.

version 4 : removed supports. It didn't work.

This thing was made with Tinkercad. Edit it online https://tinkercad.com/things/7xWR1K1K2yi

Instructions

You'll need a couple of 1/4" hex bolts and wing nuts or thumb screws to tighten the sections onto the pipes.