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3.5mm Patch Cable Cap (TPU 95A HF) 3D Printer File Image 1
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3.5mm Patch Cable Cap (TPU 95A HF)

Meat Squeezer avatarMeat Squeezer

February 8, 2026

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Description

I have had issues in the past with my modular synthesizer patch cables incurring oxidation...which leads to unreliable connections between modules as well as regular cleanings with DeoxIT.  I decided to create an end cap for my 3.5mm cables so that they are no longer exposed to the air, thus eliminating (or at least slowing down) oxidation.  

I went through multiple iterations of this model and originally printed it using PLA.  This was a mistake because I've found that not all 3.5mm plugs are created equal.  They actually seem to vary in size, ever so slightly.  I think this is dependent on the manufacturer.  I found that I had to make slightly dimension differences in order to accommodate the various brands of patch cables I own.  This was a pain, for many reasons.  

Fast forward several months and I now own some TPU 95A HF.  It occurred to me one night that I should simply print the cable caps using TPU so that they are flexible enough to fit any 3.5mm plugs.  This turned out to work superbly!  I now have what seems to be a one-size-fits-all 3.5mm cable cap and I've put them on all of my patch cables without a single issue.  

I know I am obviously not the only one who has dealt with patch cable oxidation so I hope this will be a useful print for somebody else out there!  I actually tried looking online for a product like this but I couldn't find anything whatsoever...apart from very basic sheaths that are incredibly slim and would be annoying to remove and replace.  My cable caps have some shape to them so that you can very easily grip them to either insert or remove a cable from them.  

Be aware, it does take quite a while to print these properly and I needed 176 of them myself because I have 88 patch cables.  It took me a little less than a day of printing them off and on, in batches of 14.  I experimented with printing them by layer as well as by object.  I found that, while printing by layer is much faster, it also produces sloppier results.  You get some stringing on most of the cable caps and the occasional tiny hole on a few of them.  When I printed by object, I had to settle for printing much fewer of them (since they need to be spaced apart) and they printed slower...but the results are much cleaner!  That's my preferred method and what I recommend.

I'm sure you can use various forms of TPU filament, it doesn't necessarily have to be TPU 95A HF, this is just what I own and what I know to work.  Keep in mind, because this is TPU, I ensured I dried it in a Sunlu S2 3D filament dryer for 12+ hours and I routed the TPU from the dryer to the Bambu A1 during printing.

License:

BY-NC

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