Fully Customizable Parameterized TPU Bushing

Press the Customize button to customize!

This OpenSCAD script generates a highly customizable sway bar bushing, designed primarily for automotive or mechanical applications where a "D-shaped" or cylindrical bushing is required. It features integrated grease management and easy installation options.

Features

• Fully Parameterized: Adjust bar diameter, body size, and length to fit any application.
• D-Shaped or Round: Toggle between a flat-bottom "D-shape" for bracket mounting or a standard cylindrical profile.
• Integrated Grease Channels: Includes internal V-shaped grooves to retain lubricant and ensure smooth operation.
• Grease Injection Hole: New option to add a dedicated grease port at any angle and size for maintenance without disassembly.
• Easy Installation: Optional installation slit (with adjustable angle) and a splitting feature to print the bushing in two halves.
• Retention Flanges: Optional end flanges to prevent the bushing from sliding out of its bracket.

How to Use

1. Use the MakerWorld Customizer to set your dimensions.
2. Export the STL.
3. Download the optimized print profile from this page, delete the sample models off the plate, and import your STL into it.

Customization Guide

Bushing Dimensions

• bar_diameter: The exact diameter of your sway bar.
• body_diameter: The outer diameter of the main bushing body.
• body_length: The length between the flanges.

Mounting & Base

• include_square_base: Set to true for a D-shaped bushing with a flat mounting surface.
• square_height: How far the flat base extends below the center of the bar.
• include_flanges: Adds retention rings to the ends.

Grease Management

• include_grease_channels: Cuts internal rings into the bore to hold grease.
• include_grease_hole: Adds a hole through the body for a grease fitting or manual lubrication.
• grease_hole_angle: Position the hole exactly where your bracket or access point allows.

Installation

• install_slit: Adds a cut so the bushing can be "wrapped" around the bar.
• slit_angle: Align the slit away from the primary load direction.
• split_bushing: Cuts the entire model in half (useful for printing in two rigid pieces).

Safety Disclaimer

WARNING: This part is intended for off-road or experimental use only. Suspension components are critical to vehicle safety. A failure of a sway bar bushing can affect vehicle handling and stability. Use 3D-printed parts in automotive applications at your own risk. Always inspect parts regularly for wear, deformation, or cracking.

Printing Recommendations

• Material: TPU (95A) is highly recommended for its durability and flexibility. Rigid materials (PETG/ASA) can be used if split_bushing is enabled.
• Wall Loops: 4-6 loops for structural integrity.
• Infill: 40-100% depending on the required stiffness.
• Orientation: Print vertically (standing up) for the best surface finish on the bore and flanges. No supports are typically needed for the internal bore.