Terminal Block / Wire Connector ( Feat. optional cable relief and bridging )

I wanted to have nice connectors for the extension of my MK3's PSU cables without having to tear down the entire cable harness. Since there were no proper screwing terminal blocks available out there, I did it maker style and designed my own. Measures were taken from my original black Delta PSU's terminal block. So dimensions should be really close to that.

My design additionally features an optional part for cable relief that can be attached from the top on both sides.

Bridging individual terminals is also possible by inserting a 1.5mm² ( 1.3mm Ø ) solid copper wire which is commonly used in electrical installations into the square holes on the sides. Fasting the screws will establish conduction thanks to the nuts.

Printing in PLA or PETG at 0.2mm layer height with 2 perimeters, 15% infill and a 0.4mm nozzle should do. Enable brim if the walls cause adhesion issues.

Additional parts required for each terminal:

• M4 nut ( max. 2.5mm in thickness )
• 6-10mm M4 screw
• 1-2x M4 washers ( One above and optionally one beneath the cable connector. 9mm square washers are your best choice if they're somehow available for you. Round ones tend to turn the cable when you fasten the screws. Alternatively, you could use M5 square nuts instead of washers. )

Optional parts:

• 2mm cable ties according to the favored terminals
• 2x M3 screws + 2x T-nuts for extrusion attachment or other screws for wood attachment etc.
• 22-43mm 1.5mm² ( 1.3mm Ø ) solid copper wire ( length depends on the number of terminals you want to bridge )

ToDo:

• Recreate cable relief from scratch
• Provide cable relief for each variant

History:

• 23-11-04: Recreate main part from scratch, Provide Fusion 360 F3D file, Provide main variants with 1 - 6 interfaces (STEP+STL), Fix typos in description
• 22-04-14: Initial release