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Tiny Traffic Cone

The traffic cone is a powerful symbol. It represents boundaries, safety, and caution. In the chaotic fullness of life, may we all have access to these protections. In the porousness of that which transcends the bounds of life, may we all be conscious about the ways we perceive and actualize separation.

This is a 3d-printable snap-together 1/10 scale model of a traffic cone. The printed cone with the stacking base is approximately 71mm tall, 36mm x 36mm wide, and weighs 4g.

Status

As of version 1.0.0, the Cone and Bands part of the design is satisfactory and are not expected to change. Design effort will shift to varieties of bases. Currently, there is a stacking base that is excellent for forming a stack of cones (which stick together if pressed, try it!). There is also a magnetic base that accomodates 4 6x2 magnets. The next bases are a penny weighted base, a tape base (this should be pretty basic, just remove the hole), and a zip tie base.

The FreeCAD file is the work of someone who is new to the software, so probably rough quality. Many of the parameters can be changed using the 'parameters' sheet in the file.

Model

This model was generated in FreeCAD v1.0.0.

The traffic cone reference model is the 28" traffic cone with 6" and 4" reflective bands.

Spec source: https://www.cabletiesandmore.com/jbc-safety-white-traffic-cones

Design

Values:

  1. Excellence in design
  2. Minimize waste
  3. Face a challenge

Goals:

  1. Scaled model that complies to regulations
  2. Sized to hold in the hand
  3. Minimal filament usage
  4. Break into components to allow iterating on parts with minimal time/filament waste for testing
  5. Combine parts in a way that allows separating them again
  6. Use FreeCAD to learn the software

Parts that I love:

  1. It utilizes vase mode (or mock vase mode) to make a strong print with a single wall.
  2. The bands snap onto the cone with a satisfying click.
  3. When stacked, the cones 'grab onto' each other when pressed together. This appears to be caused by the layer lines 'locking' together.
  4. The slide base holds everything together quite well after sliding together. It has withstood much handling.

Findings:

  • The cone base needs to be about 4 layers of solid infill to make a robust joint with the cone.
  • To achieve a similar snap on the upper and lower bands, the length of the tabs along the polar angle has to be smaller in the lower band - this is due to the radius being larger for the lower band. There is an equation for this, I just used intuition after testing with the same polar angle.
  • Using vase mode (or mock vase mode) creates some complexity in printing but allows for easier modeling - there is no need to model the inner part of the cone (which is complex!) or bands.

Print Instructions

All models are printed using the following settings:

  • 0.2 mm layer height
  • 0.4 mm nozzle
  • 0.45 mm width

With variations between printers and filaments, the fit parameters may need to be customized. To customize fit, see the FreeCAD file 'parameters' sheet for fit dimensions:

  • 'fit' - cone/band fit
  • 'base fit' - cone/base fit
  • 'slide fit' - base outer / slide inner fit

Bands

Load 'tiny-traffic-cone-BottomBand.step' and 'tiny-traffic-cone-TopBand.step' into the slicer. Add as many instances as desired.

Enable vase mode. Set bottom solid layers to 0. Enable 'Complete individual objects' and confirm the sequence of object print works with the printer configuration (e.g. ensure objects in front are printed first).

These settings are included in 'tiny-traffic-cone-bands.3mf'.

Cone

Load 'tiny-traffic-cone-Cone.step' into the slicer.

Regular Mode

Mock vase mode with the following settings:

  • number of perimeters: 1
  • top and bottom solid layers: 0
  • infill: 0%.

Add a modifier slab that is 0.8 mm tall and wider/deeper than cone bottom (~35mm). Position the modifier so that it covers the base of the cone. In the modifier, override bottom layers to 4.

Add as many instances as desired.

These settings are included in 'tiny-traffic-cone-Cone.3mf'.

Vase Mode (untested with latest model) - One model at a time

Enable vase mode. Set bottom solid layers to 4.

These settings are included in 'tiny-traffic-cone-Cone-vasemode.3mf'.

Bases

Base Outer

The outer base is the top part of all the following bases.

To print it, load 'tiny-traffic-cone-SlideBaseOuter.step' into the slicer.

Align SlideBaseOuter so that the flat plane (top of the base) is on the bottom, touching the build surface.

Set seam position to Random.

These settings are included in 'tiny-traffic-cone-base.3mf'.

Slide Base

Load 'tiny-traffic-cone-SlideBaseInner-Stacking.step' into the slicer.

Magnetic Base

Load 'tiny-traffic-cone-bases-BaseInner-Magnet-6x2.step' into the slicer.

Orient the model so that the bottom of the base is touching the build surface.

To add 6x2 magnets to the base, press them into the holes with a flat surface (I use flat-nosed pliers). Then pop them down into the pocket with the pad of your finger. They should be right up against the bottom of the hole.

To remove the magnets, use a 2mm hex wrench to push up from the bottom of the base.

Construction Instructions

Use some force to snap the bands onto the cone.

Orient the slide base outer part so that the octagonal indent is up. Drop the cone in tip first so that it rests in the octagonal groove of the base and extends downward. Orient the slide base inner part so that the largest surface is facing the outer part. It should slide in without much effort.