Summary

The light switches in my house are rocker switches. The problem with these switches is that they fail mechanically within a few years. Always the same problem: the plastic frame breaks. I do not mind buying new ones, they are cheap. But I do hate the hassle of replacing them that frequently. When yet another switch broke, I took the switch apart and quickly concluded that I could probably design and build something more sturdy using my 3D printer.

The faulty part could be replaced with a single 3D printed part but only with a lot of supports. So I decided to replace the part with two printed parts, without supports. The combined new part is (in my opinion) much stronger than the original part and hopefully should last much longer.

Obviously, not all light switches are the same. So far, I found two types in my house and I am including the 3D models for both types. Lighted switches are supported in both types. How do you know which type you will need? You will first have to take the switch out of the wall. Compare the plastic frame of the switch to the Type 1 and Type 2 frames and see if one of them is a match. If you run into a switch that is different, you will have to modify my design.

Watch the video to see how to take apart a switch and how to rebuild it.

Regarding the machine screws that you need for Type 1, these are #4 screws, 5/8 inch long.

And yes, the frame in the pictures and in the video is yellow for clarity reasons.

Both the Type 1 and Type 2 frames have three small semi-holes on each long side. This allows you to easily recognize repaired switches.

Last but not least, be careful, you are dealing with 110V here, do not take any chances.

https://www.youtube.com/watch?v=P1ly2W10LCs