Reproduction mirror switch project

[Rhye]

Hi everybody,

I'm currently running a reproduction mirror switch project and decided to share it with the community since I guess at least some of you may find it interesting. The switch will be totally redesigned inside, using as many standard components as possible. The goal is to make it more reliable and user-friendly while keeping external appearance as close as possible to original. An optional LED backlit decal is also being considered. MJF or SLS technology will be used to manufacture all custom mechanical parts of polyamide.

shaded_1.jpg

If everything goes well with design and prototype testing, a short pre-production series should be available by the end of 2019. The price of final version is estimated to fall between $160 and $200, assuming 20pcs minimum production run.

As for the progress, an early pre-prototype has already been FDM 3D-printed, just to check some initial design ideas and general appearance:

IMG_20190315_203459378~2.jpg

At the moment, mechanical design of 2 different prototypes is almost ready and MJF 3D-printed parts will be ordered soon:

transp_1.jpg transp_2.jpg

I'll keep posting updates as project advances.

[Patrick C]

Wow! Great idea!

[Farrar]

This is a great idea! I just wish 3D-printed stuff didn't look so "layered."

[Parzival]

This is a great idea! I just wish 3D-printed stuff didn't look so "layered."

Is just the prototype 3d printed to check the design? The production part will be molded?

[Rhye]

Is just the prototype 3d printed to check the design? The production part will be molded?

Final parts (and the two soon coming prototypes) will also be 3D-printed, but in totally different technology than the FDM pre-proto part. Surface finish will be like on the sample close-up attached below or even better, depending on post-processing method used:

MJF_sample.jpg

[Parzival]

Ok cool, can’t wait to see how those come out!


Sent from my iPhone using Tapatalk

[mluder]

Great project!

Cheers
Steve

[dn010]

So this won't be using the steel ball/spring setup as originals did internally? It's a shame, I just rebuilt mine but could do with an upgrade as it is still a bit finicky.

[DavidProehl]

Great project! Will the internals be compatible with original shells? That would be helpful for repairing broken originals.

[Rhye]

Will the internals be compatible with original shells? That would be helpful for repairing broken originals.

No, it will be totally different animal inside - PCB with some standard electronic components will be used.

If there's some need for spare parts for original switch, I could check if it's feasible to 3D-print them, but I need to finish reproduction design first.

If you think of upgrading original shell with new internals - well, that seems possible, but also needs a separate project.