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garygid
Gold Member
Posts: 12465
Joined: Wed Apr 21, 2010 8:10 am
Delivery Date: 29 Mar 2011
Leaf Number: 000855
Location: Laguna Hills, Orange Co, CA

Re: SAE J1772 inlet port Dimensions

Sat Mar 16, 2013 11:17 am

Smidgen,
Where are you located?
It is most likely that we could arrange for a test fitting.

I would check the clearances before printing, to make
sure that any surface "roughness" (variations) will
not interfere with the fit of the J1772 plug.

What kind of 3D printer do you have available?

What material do you use with it?
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borland
Posts: 45
Joined: Sun Aug 08, 2010 5:39 pm

Re: SAE J1772 inlet port Dimensions

Sat Mar 16, 2013 12:40 pm

Smidge204 wrote:How big is it? I might give it a go in my printer just for laughs.

Though I don't have any connector to test fit with.
=Smidge=
It's actually smaller than it appears in the sketch.

base is: 70 mm x 65 mm x 5 mm thick
tube is: 5 mm thick x 50 mm O.D.
overall height is: 70 mm

PM me if you want the STL file. Dimensionally, it is correct, but I'd need to do some additional QC checks before releasing the file.

Smidge204
Posts: 940
Joined: Wed Nov 24, 2010 1:42 pm

Re: SAE J1772 inlet port Dimensions

Sat Mar 16, 2013 1:06 pm

garygid wrote:Smidgen,
Where are you located?
It is most likely that we could arrange for a test fitting.

I would check the clearances before printing, to make
sure that any surface "roughness" (variations) will
not interfere with the fit of the J1772 plug.

What kind of 3D printer do you have available?

What material do you use with it?
Long Island, NY

I use a FDM type printer running PLA (poly-lactic acid). It's a biodegradable plastic with a low glass temperature (~60C/140F) not terribly suited for hot things :) Not sure how it's survive being exposed to the elements but it makes for some nice mechanical bits.

Here's an up-close picture of what the finished print surface looks like. By default I print with 0.25mm layers so that's the height of the ridged you see there... I don't think that kind of roughness will be a problem.
=Smidge=

Smidge204
Posts: 940
Joined: Wed Nov 24, 2010 1:42 pm

Re: SAE J1772 inlet port Dimensions

Tue Mar 19, 2013 5:32 pm

The deed is done :ugeek:



Tomorrow afternoon it'll be on its way across the countryside.
=Smidge=

ILETRIC
Posts: 740
Joined: Sun Dec 19, 2010 9:36 pm
Delivery Date: 04 Jun 2011
Location: Marin County

Re: SAE J1772 inlet port Dimensions

Tue Mar 19, 2013 6:12 pm

I made this before I even got my Leaf in 2011. Have been using it ever since. Got one request to make one from England (of all places).


Image

Image
------------------------------------------------
1st bar lost at 38,700 miles/22 months
2nd bar lost at 45,750 miles/27 months

Traded-in on 10-19-2014 at 56,150 miles
-------------> for Kia Soul EV+ <-------------

dzd
Posts: 33
Joined: Mon Dec 10, 2012 3:15 am
Delivery Date: 10 Dec 2012

Re: SAE J1772 inlet port Dimensions

Thu Mar 21, 2013 1:01 am

nice job Borland!!! if the fit is good would you make the file available or put it on file with shapeways so we can all partake?

borland
Posts: 45
Joined: Sun Aug 08, 2010 5:39 pm

Re: SAE J1772 inlet port Dimensions

Thu Mar 21, 2013 10:34 am

dzd wrote:nice job Borland!!! if the fit is good would you make the file available or put it on file with shapeways so we can all partake?
Looks like Smidge did a great job on printing the part. The short video is is very impressive too.

As soon as the part arrives, I'll post a photo showing the fitup with my J-plug.

Smidge makes it look much easier than it is to print. The drawing can be dimensionally correct, but depending on how well the 3D printer is calibrated, the part can come out a different size. There are other printing factors that affect sizing too.

Smidge said that his printing software estimated the cost of PLA filament to be $2. I'm not sure what Shapeways charges for a part this size or how accurate their printers are. Something I need to inquire about (cost and quality).

If this part is going to be widely made, I'd like to add a freeze protection cover above the latch so the part could be used outdoors.

borland
Posts: 45
Joined: Sun Aug 08, 2010 5:39 pm

Re: SAE J1772 inlet port Dimensions

Sat Mar 23, 2013 6:32 pm

Thank you Smidge204!

The part arrived in the mail today. Looks great. Fitup with the J-plug is good; plug snaps in place with no interferences. The screw hole sizes and screwdriver access are good also.

Here's some photos showing fitup with my J1772 plug (manufactured by ITT)....you can see that the part was printed with honeycomb infill...

Image

Image

If mounted to a wall, the J-plug handle points straight down.

Image

Image

You can see in this photo, it's not a tight fit. Printing tolerances make this difficult to size precisely.

Image

My J1772 has a foam gasket seal around the outside of the plug. When connected with the part, the gasket is barely compressed. Not sure if other J-plug have this feature.

Haven't done any destructive testing, but the part looks to be strong enough. Only design change I'd make, is to shorten the tube by a few milimeters.

User avatar
TonyWilliams
Posts: 10091
Joined: Sat Feb 19, 2011 1:48 am
Location: San Diego
Contact: Website

Re: SAE J1772 inlet port Dimensions

Sat Mar 23, 2013 6:35 pm

borland wrote:Haven't done any destructive testing, but the part looks to be strong enough. Only design change I'd make, is to shorten the tube by a few milimeters.
I'd put a gusset underneath the assembly and lower the two bottom mounting bolts a few inches.

ILETRIC
Posts: 740
Joined: Sun Dec 19, 2010 9:36 pm
Delivery Date: 04 Jun 2011
Location: Marin County

Re: SAE J1772 inlet port Dimensions

Sat Mar 23, 2013 8:23 pm

How about making a mold out of it and proceed from there... I like it!
------------------------------------------------
1st bar lost at 38,700 miles/22 months
2nd bar lost at 45,750 miles/27 months

Traded-in on 10-19-2014 at 56,150 miles
-------------> for Kia Soul EV+ <-------------

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