HEXEN - Flexible Cable Protector

HEXEN - Flexible Cable Protector

Flexible cable protection – for your chargers, phone or USB cables and anything else that needs protection from damage

There are many models designed to protect cables, but none of them really suited me. I decided to design my own – not only functional, but also as versatile as possible.The design was a little bit complicated (like witchcraft) ... & together with its shape, determined its name – HEXEN.

Two main types of HEXEN

• HEXEN Solo – a simpler version, just the "bare" body of the protector – without End Caps. Useful when you need to protect a cable somewhere in the middle or where the cable has the same diameter on both sides of the protector.
   
• HEXEN Combo – the body of the protector is identical to the Solo model + also allows installation of End Caps. Ideal for protecting the cable at its end, where the cable has often a different (larger) diameter or connects to a shaped connector.

End Caps are also useful if you want to better secure the cable in the protector (the end caps rotate after the cable is installed). 

There are three types of End Caps: 

• EndCapA - Round for thickened cable diameter
• EndCapB - Round for the same cable diameter
• Square EndCap – for cable end with shaped connector

The End Caps are printed separately and snap into the HEXEN body. Once installed, they hold securely but still allow rotation.

Tip: HEXEN Solo does not support the installation of End Caps. For better distinction Solo has a tapered shape at the ends, while Combo has straight ends and has "cutouts" in the body for installing End Caps.

Configuration options

The flexible design of HEXEN allows you to configure many features, which can be a bit confusing at first. However, you gain the ability to create the protector you exactly need (and moreover you will soon find configuration quite simple).

Here are the main setting options (all values are in millimeters - mm):

• Cable Dia(meter) - main parameter - specifies the diameter of the cable for which HEXEN is intended. It is important to enter this correctly. A large protector will not stay on the cable, and a small one will be difficult to install. 
  The acceptable values range from 2 to 9 mm.
  
  Technical note (applies to all parameters): if "incorrect" values are entered, they are adjusted to the nearest possible correct value, so the model can be successfully generated and printed.
  
  Tip: Due to the properties of the 3D material (shrinkage), it's useful to select a value slightly larger (approx. 0.2 to 0.3 mm) than the actual cable diameter - e.g., for a cable with a diameter of 3, select a size of 3.2 or 3.3 (a smaller value is more suitable for the Hexen Solo model). If you do not know the properties of the filament used, it may be useful to print a small (short) test Hexen, just to verify that the selected diameter is ideal.
   
• Body Length - specifies the length of the main body of the HEXEN (without End Caps). 
  The Acceptable values range 20mm - 230mm
   

• Body Size - the size of the HEXEN body - specifies how "thick" the protector will be and the related properties - how flexible, strong, etc. 
  The minimum value is "Cable_Dia" + 7mm (3.5mm on each side).
   

   

The following parameters are only used by the "Combo" model with End Caps

• Type 1 - Round EndCapA - used where the cable diameter changes/increases before the connector and you want to protect this part as well. The following parameters can be selected for the EndCap-A End Cap:
  
  EndCapA_Dia – cable diameter where the cable is thickened. If the cable is not thickened, use the same value as the cable diameter (CABLE_DIA). The minimum value is the Cable diameter (logically, the reinforcement cannot be smaller than the diameter of the main cable).
  
  EndCapA_Length = outer length of the end cap. (Min = 5mm)
  
  

• Type 2 - Round EndCapB - most often used at the other end of HEXEN - where the cable normally continues. This is usually a smooth transition from HEXEN to the cable itself. EndCap-B always has the same cable diameter as the main part of HEXEN (because there is usually no thickening on this side).
  
   EndCapB Length = length of the second end cap (Min 5mm)
   

• Type 3 - Square EndCap - is an alternative to EndCapA. It is suitable if the cable ends in a shaped square connector, which also needs to be protected. It is defined by these 3 parameters:
  
  Square_Width and Square_Height - internal sizes of connector. Minimum must be greater than the diameter of the cable + 0.2mm
  Square_Length - length/depth of connector - min 5mm
   

• ENDCap_Fit - (advanced parameter)  determines the tightness of the connection between the Hexen body and the EndCaps. 

  The standard value “0” is suitable for common materials such as PLA, PETG, PA, etc. However, if you use softer and more flexible filaments such as TPU for AMS or TPU, the connection may be a little bit loose (but still works). In such case, use the "1" setting - the connection will be generated tighter. 
  
  Note: Do not use the value 1 for PETG, etc. as the EndCaps would probably not fit into the Hexen body at all!  
  Only change this if you really need to. If you are unsure, leave the value at 0 (default)
   

All connectors "click" into place in the cutout in the main body of the HEXEN. Click and hold. However, it is possible to freely rotate them to the position that best suits the given application.

Tip: all connector types are interchangeable when connected to HEXEN - any combination/type of connector can be used on both sides of HEXEN - e.g., Square EndCap on both sides, or round extended EndCapA on both sides, etc... just print the desired connector multiple times.

Of course, the End caps and Main body must be generated for the same cable diameter, e.g., a body for a 4 mm cable will only be compatible with End Caps generated for the same cable diameter.

Material

• PETG - the optimal material for this model. An ideal combination - flexible enough to function reliably and yet easy to print. If possible, PETG is your first choice. For this reason, the prepared print profiles are optimized for PETG.
  
  Technical note - if  using PETG, do not use the model immediately after printing. Allow it to cool and "mature" properly - for at least several hours (ideally overnight). If you put stress on it too soon, it may crack (unnecessarily). If you give it the time, you will be surprised by its durability and flexibility. Another factor that causes brittleness is moisture. Print from properly dried PETG.
   
• PLA - HEXEN is also functional to a certain extent when printed from PLA. However, PLA has its limits, especially in terms of flexibility. If Hexen is to function more as a preventive measure, it should be OK. However, if you repeatedly expose it to serious bending, it may crack. 
  In such case, please do not blame the model, but choose a more suitable material.
   
• Other recommended materials - an excellent material for HEXEN is Bambu TPU for AMS. Sufficiently durable, flexible, easy to print (AMS). If you have it, don't hesitate.  Another great material that can withstand almost any stress is Nylon (PA), which, however, may not be available to most users.

Important - if you use the CUSTOMIZE function and generate HEXEN according to your specifications, the generated print profile (3MF) will be set to PLA as the base material and standard (high) print speeds (neither of which are optimal). 

Unfortunately, in the current version of the Customize Generator, I am unable to control either the material or the speeds in the generated profile. These need to be changed/set manually afterwards - more information can be found below…

Printing

if possible, I recommend using the attached Print Profiles, which are optimized for trouble-free printing and use. If you still decide to use your own print profile, keep the following parameters in mind:

• Recommended filament: PETG
• 0.16mm High Quality - layer height 0.16mm
• Generator (Quality) Arachne
• Seam (Quality) Random
• Wall Loops (Strength) 3
• Sparse Infill (Stregth): Gyroid
• Speed: for PETG: Initial Layer 50; other speeds max 150 (less is better) The model has fine details that are important, so a low speed is appropriate. In addition, using a higher speed will save you minimal time and unnecessarily risk the quality and functionality of the model.
   
• Support: The main body of HEXEN does not need any support. But it may be needed for the End Caps (EndCapA and SquareEndCap), depending on the parameters with which they were generated. Therefore, support is generally allowed, and the decision whether to use it or not is up to the slicer for each specific case. In addition, any support is minimal (a few mm) and, most importantly, easily removable.
  
  Recommended Support settings: Yes-enabled; Type: Tree-auto and Style: Default; Support Critical Regions Only: ON; Remove Small Overhangs: ON

What to print – which version to choose

The model includes two pre-configured Print Profiles + an additional CUSTOMIZE option, which generates HEXEN Combo according to user's request. 

If you are only interested in the CUSTOMIZE version, skip to the next paragraph.

Due to the wide range of configuration options, it was not possible to include all combinations, so the selection is somewhat limited to "standard" sizes. Even so, there are many options - you will choose the version that interests you. Of course, you don't have to print everything that is included in a given profile :-)

Print Profile_1 - HEXEN Solo

HEXEN Solo is a "simplified" version - only the main body of the protector, without the option of installing additional End Caps. Suitable for cases where the protector alone is sufficient.

Print Profile Hexen Solo contains 5 plates:

• Plate_1  - various lengths of HEXEN Solo for cables with a diameter of 3 mm
• Plate_2 - various lengths of HEXEN Solo for cables with a diameter of 3.5 mm
• Plate_3 - various lengths of HEXEN Solo for cables with a diameter of 4 mm
• Plate_4 - various lengths of HEXEN Solo for cables with a diameter of 4.5 mm
• Plate_5 - various lengths of HEXEN Solo for cables with a diameter of 5 mm

Tip: For more detailed information about individual object, click on the specific item – its name contains its dimensions:

HEXEN_Solo-xx-yy-zz  where xx is the cable diameter, yy is the length of the HEXEN body, and zz is the size of the body (detailed explanation of the parameters above) … e.g.: 3,5-50-14  is the Hexen Solo model for a 3.5mm cable, with a body length of  50mm and a body size of 14mm.

If none of the sizes in this Print Profile suit you:

• use the CUSTOMIZE function to generate a HEXEN Combo model exactly according to your requirements.
• if you insist on the Solo model in unavailable size, please let me know. I will generate the desired size for you upon request.

Print Profile_2 - Hexen Combo

Because Hexen Combo offers such huge range of configuration options (dimensions, combinations of different parts), it is not practically possible to include even a significantly limited selection in the print profile. This would be impractical from a maintenance (update) perspective for the designer, and it would also be difficult and confusing for users to navigate the flood of objects.

That is why Hexen Combo relies exclusively on generating "CUSTOM" model using the Customize function

The pre-prepared print profile therefore contains only one SAMPLE model with the following specifications (cable diameter 4 mm; body length 40 mm; body size 12 mm; EndCapA with thickening to 5 mm and length 8 mm; EndCapB with a length of 6 mm; Square EndCap with dimensions of 19 x 5 x 10 mm)

Please note, this particular model is only a "sample" and is 99.9% NOT the one you need or want to print. To create your own HEXEN Combo with specific dimensions, use the Generator via the CUSTOMIZE function.

The reasons for the existence of this "sample" are as follows:

• the model needs its own profile for presentation at MakerWorld - among other things, as a space for publishing real photos.
• more important - print profile contains recommended print parameter settings - which is very useful for later printing of the generated model to order (see below for more).

CUSTOMIZE - generating a Custom HEXEN Combo model

Note - the generator ALWAYS generates the complete HEXEN Combo assembly - 4 parts (Main Body, EndCapA, EndCapB and SquareEndCap), even if you do not need some of the parts. Unfortunately, my license of Fusion360 CAD program (in which the model is created) does not allow for the conditional generation of individual components. Therefore, the generated and downloaded 3MF file will always contain the complete set of 4 parts. If you do not want a certain part, simply do not print it.

1. To start the generator, press the CUSTOMIZE button.
   
   
    
2. The screen shows a workspace where you can enter the desired parameters (all values are in mm). If you are not interested in a particular part, you can leave its parameters at their default values. A detailed explanation of each parameter (what it means, what values and/or limitations are) is provided above at the beginning of this description in the "Configuration Options" section.
    
3. After entering the parameters, press the GENERATE button and wait for the model to be generated (... this may take a while). 
   A message indicating that the action is complete and the resulting model will appear on the desktop
   
   
    
4. Now you can download the generated model as a 3MF print file. Or change the parameters and repeat the generation.

Important note - the generator for Fusion models on MakerWorld does not work perfectly - it does NOT allow me to set all the print parameters that I consider appropriate and with which the model was tested. This mainly concerns the type of material (filament), print speed, and layer height. 

All those are beyond my control - they are set automatically by the generator to default values - material to PLA and standard speed for PLA printing and layer 0.20mm.

As mentioned above in the "Material and Printing" section, neither PLA nor the default speeds are optimal for the HEXEN model (although they may work to a certain extent). Therefore, I recommend adjusting the print parameters before printing:

•  You can adjust the print parameters yourself manually - recommended setting was mentioned above
•  The second option (RECOMMENDED) is to adopt the COMPLETE print settings from the pre-prepared Print Profile.

Here are instructions on how to do this in 5 easy steps:

1. Download the pre-prepared PrintProfile "Hexen Combo" from the model page (you are not interested in the sample model itself, but want to use the print parameters set in it) ... and open this file in Bambu Studio. 
   
   The file will be named RC-Hexen_Combo-Vxx.3MF ("xx" is the working version number, which may change over time).
    
2. LEAVE all Sample objects on Plate_1 and Create NEW Plate → press the “Add Plate” button on the Top Bar 
   
   
   
    
3. You now have a new blank plate (the plate should be active/dark in color. If it is not, click on it to Activate).
   The next step is to import the generated model –> press the "Add" button on the top bar and select the generated/downloaded file from the CUSTOMIZE generator to open it.
   
   The file will be named HEXEN_Combo_RC-Customize_Vxx.3MF (again, "xx" is the version number, which may change over time). 
   
   
   
   IMPORTANT: When asked how you want to add the file, select the "IMPORT GEOMETRY ONLY" option. This ensures that only physical objects (generated model parts) are loaded, but the print settings remain unchanged from the original profile... This is exactly what we need.
   
   The generated HEXEN Combo model is now located on new Plate - all 4 parts, while original print parameter settings, including the recommended PETG material, speed, etc … remain unchanged - Success / Great ! 
    
4. If you want to print everything, proceed directly to step 5.
   
   If you don't need a certain part and want to delete it, you must first divide the model into individual objects - press the "O" button on the top bar. The model assembly will be "broken down" into individual objects, and you can now select the "unwanted" one and delete it.
   
   
    
5. Then proceed as normal - "Slice Plate" and then “Print Plate”

That's all folks... at least I think so :-)

Yes, I admit that's quite a lot of information for such a small model, but I believe that once you try it, you'll see for yourself that it's definitely not "small." Maybe in terms of its dimensions, but definitely not in terms of its capabilities.

I hope you like it and, above all, that it serves you well ... Enjoy!