Summary

I made these to replace some that students broke on some PASCO equipment but they will have other uses.

They work well for me. I think I prefer using hex bolts rather than socket head (Allen) bolts because they are cheap and I think they will give me more torque, though I have not tested this. None of mine have broken yet.

In my application, I use a simple plastic washer between them and the aluminium part they are clamping.

There are files for hex head bolts and for socket head (Allen) bolts, both 1/4-20. Mine were 1" long but you could use any length.

I sliced with Cura and printed them on an Artillery Sidewinder X1 with the following settings and material:

• PLA (I used black from Tinkerine)
• 0.2mm layer height.
• 10% gyroid infill.
• 2 shells.
• Extruder temperature: 210 degrees C.
• Build plate temperature: 55 degree C.
• No support.
• Brim on. Though this is probably not necessary.

Assembly

• Place a liberal amount of super glue in the part I call the "Wings" and then seat the bolt well into that part making sure it is aligned properly.
• I then put a few dabs of super glue on the mating surfaces of the "Wings" and the bolt and slide the "Cap" on, pressing it down firmly and, again, making sure it is aligned properly.

230328 UPDATE
I noticed that the new hex bolts I have had a larger head. This design was for heads of ~9mm diameter.
It does not fit 10mm heads. I will try to find time to update the STL and then post it here.