Flex-Lock - Load-bearing beams that print in-place

NEW! Updated design with 3 sizes available (300mm, 450mm, 600mm)

This is a concept I've been working on for printing load-bearing beams longer than your build volume allows; the model prints in-place as a single piece and snaps together to form a beam. As the name “Flex-Lock” suggests the design consists of two parts; a flexible connector that doubles as a tensioner when the system is under load and a locking mechanism that aligns and connects the two pieces together. The print is oriented in such a way that the majority of forces applied are along the XY print plane which minimizes issues due to layer adhesion.

Interested in a practical use case? Checkout my IKEA filament rack which uses a pair of these beams to support four spools of filament.