Starlink Mini Flat Mount REV 3

Starlink Mini Dishy Flat Mount – REV 3

What’s New in REV 3

REV 3 is a complete redesign focused on better protection, greater versatility, and simpler assembly.

• Improved geometry for increased durability
• Full‑coverage upper shell for protection
• Optional handle for easier removal from vehicle roofs
• Optional hard‑mount wing for expanded mounting configurations
• Simplified 5‑piece design for faster printing and easier assembly

Recommended Print Settings

The one piece upper cover requires an H2S or similar large‑bed printer.

The two piece upper cover can be printed on any H2 series or similar large-bed printer.

The four piece upper cover can be printed on any printer with a bed size larger than 190mm x 180mm

• The 4 piece upper cover is untested so please provide feedback if you do print one. 

   

Thank you to Schlagel Bagel for the idea and testing the print of the two piece cover.

Print Parameters

• Layer height: 0.2 mm
• Infill: 35% Gyroid
• Walls: 6 perimeters (4 may be acceptable depending on material)
• Material: PETG, ASA, or ABS recommended. ABS‑GF is preferred for maximum rigidity.
• Supports:
  • Required only from build plate
  • Needed for screw recesses and joint features
  • Support interface recommended for clean removal

Included Print Profiles 

Profiles are tuned for ABS‑GF using BambuLab Support for ABS as the support interface. They include a specific Z‑offset for easier support removal. 

Do not use 0 mm Z‑offset.

Mid‑Print Hardware Insertion 

The upper cover requires M6 locknuts inserted mid‑print. A pause is included at layer 51 in the provided profiles.

Make sure nylon portion of locknut if facing the build plate.

Optional Customization

The upper cover features a hexagon pattern that can be printed in a contrasting color. Two windowed areas allow for optional text or graphics—ideal for:

• Dish identification
• Wi‑Fi details
• Contact information
• Custom logos (I print my logo in the center window)

Hardware Required

• 4× round puck magnets
  • Example: BQUKKIMAG 5Pack Rubber Coated Magnets D66x8mm M6 Round Magnets Strong Large Magnete with Thread, Flat Magnet with Hole Countersunk Head Pot Magnet for Screwing on Car Lights : Amazon.ca: Industrial & Scientific
• 10× M6×35 mm screws
• 4× M6×50 mm screws for magents
  • Example: M6 Bolts x 50 mm 20pcs Flat Head Hex Socket Cap Screws Bolts,Metric,Thread Pitch 1mm,Alloy Steel,Black Oxide,Full Thread,with Hex Spanner,for Furniture,Beds,TV Stands,Frames,Office Chair (20, 50 mm) : Amazon.ca: Tools & Home Improvement
• 10× M6 nylon lock nuts
  • Example: Vifmy 150 Pack M6-1.0mm Nylon Insert Hex Lock Nuts, 304 Stainless Steel A2-70 Locknuts,Standard Metric Thread Nylock Nuts for Bolts : Amazon.ca: Tools & Home Improvement

Assembly Instructions

1. Assemble the Lower Frame

• Slide the lower frame pieces together.
• Joints are intentionally tight for rigidity and may require firm pressure.

2. Position the Dish

• Place the Starlink Mini face‑down into the upper cover.

3. Attach the Lower Frame

• Set the assembled lower frame onto the upper cover.
• Ensure the PORT SIDE text aligns with the dish’s ports.

4. Install the Screws

• Insert M6×35 mm screws through the lower frame into the upper cover.
• Tighten in a criss‑cross pattern for even compression.
• Applying anti‑seize is recommended to prevent galling in the locknuts.

5. Install Magnets (Optional)

• Insert M6×50 mm screws through the magnet holes in the upper cover.
• Attach magnets to the lower frame.
• Tighten in a criss‑cross pattern.

6. Enjoy Your Mounted Dish

Your REV 3 mount is now ready for use.

Other Designs

• Original Mini Flat Mount (REV 1) – MakerWorld
  • Starlink Mini Flat Mount REV 1 - Free 3D Print Model - MakerWorld
• Original Mini Flat Mount (REV 2) - MakerWorld
  • Starlink Mini Flat Mount REV 2 - Free 3D Print Model - MakerWorld
• Starlink Gen 3 Flat Mount – MakerWorld
  • Starlink Gen 3 Flat Mount - Free 3D Print Model - MakerWorld