3D printing of scooter parts: what works, what doesn't
3D printing has revolutionized the way we customize scooters. A custom cover, a screen mount, a cable guide, or even a complete fairing can be designed and manufactured in a few days, without the need for molds. In our workshop, we use it for almost all of our customizations. However, it has its limitations: a 3D-printed part can effectively cover, protect, and organize components, but it cannot replace a metal-machined structural or safety component.
The essentials
- 3D printing is ideal for creating covers, brackets, cable conduits, enclosures, and fairings.
- The choice of plastic material is crucial: heat, sunlight, impacts, and flexibility all require different materials to address them effectively.
- A 3D-printed part is more fragile in terms of its layer structure, and the orientation for printing is determined during the design phase.
- Never use 3D-printed parts for components that handle steering, braking, or the wheel itself.
Here's what 3D printing excels at:
The covers and housings
Closing a lengthened deck, concealing a cutout, protecting a connector: these are complex-shaped parts, produced in small batches, for which a mold would not be cost-effective. Our extended deck plates for Dualtron are therefore supplied with black PETG-printed covers.
Mounting and integration
Secure a screen, controller, wiring harness, or sensor exactly where you want it. Our 3D-printed parts for Slack Core 920R combine housings, brackets, and cable channels that integrate controllers, screens, and the battery compartment into the machine. Our titanium steering column for the Teverun Fighter Mini comes with a 3D-printed screen mount, which accommodates the original screen as well as the SmartDisplay.
Cable finishing and management
On our Thunder 1 Evo, which has been modified for track use, we 3D-printed custom cable combs for the phase wires and column clamps. These are small details, but well-secured cables won't rub, vibrate, or get caught in the suspension.
The enclosures
A controller or electronic enclosure is designed around its internal components. Our custom enclosure service, available at this link, creates enclosures using 3D printing or aluminum, depending on the thermal and impact requirements.
The fairing
Our Formula Escooter project takes this idea to the extreme: a fully 3D-printed racing fairing for the Dualtron Thunder and for our extended chassis. The parts are cut to fit on the printer bed, oriented to minimize the need for supports, and assembled with keys and screws rather than glue. A damaged part can be easily replaced, and the entire assembly screws onto the battery compartment threads without requiring any drilling of the chassis.
Choosing the right material is crucial
| Material | Key Features: | Limitations |
|---|---|---|
| PLA | Easy to print, precise | Softens in the heat, whether from a deck exposed to the sun or from the controller; becomes brittle |
| PETG | More resistant to heat and impacts than PLA, and less susceptible to moisture | Less rigid than a reinforced engineering plastic |
| ASA, ABS | Good temperature stability; ASA offers good resistance to UV rays | More difficult to print |
| TPU | Flexible: seals, cable guides, bumpers | It does not conform to any rigid form |
In our custom builds, PETG is the primary material used for covers and brackets. TPU is used for parts that need to be flexible; for example, our deck kit for the Dualtron Victor includes TPU gaskets for the cable passages.
The design rules for a 3D-printed part
- Consider the layers: A 3D-printed part is made up of superimposed layers. It is stronger within the plane of the layers than it is perpendicular to them. The part is oriented so that the forces do not tend to separate the layers.
- Screw rather than glue: A piece that is screwed in can be easily disassembled, replaced, and inspected.
- Plan for inserts for the screws that will be tightened frequently: threads cut directly into the plastic wear out quickly.
- Keep away from heat sources, or choose the material accordingly, when near a controller, motor, or disc.
- `Allow for cable slack: A cable run that is too tight will eventually fray the sheathing. See our guide on how to protect scooter cables.`
Things you should never print
Certain components are critical for rider safety. Their failure can lead to accidents. These components remain made of metal, are precisely machined, and undergo rigorous quality control
- the steering column, the clamping ring, and the stem adapter
- the arms, wheel axles, and pivot axles;
- brake caliper mounts and brake plates;
- The stem and handlebars;
- Anything that secures the battery within the frame in the event of an impact.
A 3D-printed part can serve as a template or prototype to validate a design before machining. It should not be used as a final part in place of a metal component.
Workshop tip
Before printing a final part, print a quick prototype and mount it on the machine. Errors of just a few millimeters are immediately apparent, and a second print costs much less than a failed part that you force into place. Our guide on preparing the Slack Core shows how these parts fit into a complete setup.
Frequently Asked Questions
Does a 3D-printed part last?
Yes, provided the material is suitable for the environment in which it will be used. A PETG enclosure that is protected from high temperatures will last a long time; a PLA part placed near a controller will quickly deform.
Can a battery enclosure be 3D printed?
A casing that encases and protects a battery from water and dust is a good idea, provided it is well-designed and securely mounted on a metal structure. The battery must remain held in place within the casing by metal components.
Is 3D printing water-resistant?
Plastics like PETG or ASA are not affected by water. The watertightness of an enclosure depends primarily on its design: seals, overlaps, and cable passages.
Can you print a part for my machine?
Yes, this is possible as part of a custom build or enclosure. Please describe your requirements to us: dimensions, contents, mounting method, and water resistance.