The Trials of Printing Mil-Spec Connectors

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[Chris] over at the 23B hackerspace had a bit of a problem – a project required the use of a very old rotary encoder with a mil-spec connector. While it might be possible to simply buy one of these mating connectors on Digikey or Mouser, that’s not [Chris]‘ usual MO. He has a nice 3D printer, and this connector is basically a cylinder with some holes. How hard could printing out one of these connectors be?

The dimensions for [Chris]‘ first attempt at creating a mating connector came from Solidworks’ “Sketch Picture” command where an image can be superimposed over a model and the 3D features created from that guide. If it worked, it would be far too easy, and the printed model didn’t fit at all.

This failure led [Chris] to page through MIL-STD-1651, a portly tome of 200+ pages covering every circular connector possible.  After 20 minutes of scanning the specs, [Chris] found what he was looking for: the correct specification showing him where all the pins and holes should go.

After some fine modeling in Solidworks, [Chris] had his very own custom printed Mil-Spec connector. Sure, he ate up more time than it was worth for one connector, but now that he has the STL file, he can print out as many as he needs.

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