3D print an end cap for square tubing
For a square-tube end cap, measure the actual width and height of the tube. An internal plug also requires the inside dimensions or wall thickness, while an external cap is based on the outside dimensions. Do not assume the CAD mating dimension should be exactly identical to the measured tube. Printed parts need intentional clearance.
Internal or external?
Internal plug: the cap insert sits inside the tube. Measure internal width, internal height and insertion depth. External cap: the cap fits over the tube. Measure external width, external height and cover depth.
- Internal plug: internal width
- Internal plug: internal height
- Internal plug: insertion depth
- External cap: external width
- External cap: external height
- External cap: cover depth
Measure the real tube
A nominal 30 × 30 mm tube may not measure exactly 30.00 mm. Use the actual part.
Measure more than once
Check:
- multiple points
- both directions
- deformation at the cut end
Clearance
Do not simply use identical dimensions for both mating features.