DeWalt™ AirLock™ compatible twist-lock dust collector fitting

DeWalt AirLock compatible twist-lock dust collector fitting

I like DeWalt tools well enough and own a bunch, but like every other tool vendor their approach to dust collector connections is psychotic. I'm not at all convinced that any two tools share the same damned fitting.

I bought the DWH161 dust collector and DCW210 pad sander recently. Both tools are new brushless "XR" series tools. I should have read the reviews because everyone else already noticed that DeWalt doesn't seem to offer any adapters or other means to make these two things connect together. Normally, this would be a simple matter of printing a "tube" with the correct OD and ID to make things work, but the twist-lock mechanism in use on the sander was interesting to me so I set about trying to replicate the mechanism on my printer.

The resulting mechanism consists of a ring of 6 pawls that can bend toward or away from the center of the fitting. The outer ring has 6 cams that, when twisted to the lock position, will press the pawls into a matching ring on the tool. The result is an extremely secure fit, you can hang the tool by the hose when it's locked into place. The model has been designed to print without supports and has thus far lasted through several hundred insertion cycles.

DeWalt apparently is on a second-generation of the "AirLock" hose connector. The DCW210 sander uses this new style of fitting which includes some bosses around the perimeter allowing the fitting to stay stationary while twisting the locking mechanism. This allows for one-handed operation. The previous AirLock design requires two hands to twist the hose to the lock position because it will otherwise spin freely on the tool.

Assembly

The outer ring should slide freely onto the inner ring, and when all the way in the top layers should be flush. If they aren't, you have the outer ring on upside-down. With those two pieces together, you then can press-fit the hose adapter to the bottom of the inner ring. Position the hose adapter against the inner ring and then use a vice, bar clamp, arbor press, etc to squeeze the two together. The fit should be TIGHT and once pressed together I have been unable to remove the parts without destroying the plastic itself.

Dust Collectors with 1.25" (32mm) OD Hose

If you have one of these dust collectors/vacuums you should have a hose with a 1.25" (32mm) OD that will fit into the part DeWalt AirLock Inlet hose adapter 32mm ID.stl

• DWH161B 20V MAX* Brushless Universal Dust Extractor
• DCV517B 20V MAX* 1/2 Gallon Wet/Dry Portable Vacuum
• DCV580 18/20V MAX* Cordless Wet-Dry Vacuum
• DCV581H 18/20V MAX* Cordless/Corded Wet-Dry Vacuum Tools with new-style AirLock for one-handed operation

If you have a tool from the following list, this adapter will allow for one-handed connection and locking of the fitting to your tool.

• DWE6411 1/4 In. Sheet Palm Sander
• DWE6420 5" Single Speed Random Orbit Sander
• DWE6421 5" SINGLE SPEED RANDOM ORBIT SANDER
• DWE6423 5 in. Variable Speed Random Orbit Sander Kit
• DCW210B 20V MAX* XR 5 in. Brushless Cordless Random Orbital Sander Tools with old-style AirLock

If you have a tool from the following list, this adapter will connect to your tool's dust port but will require two hands to twist-lock the fitting to your tool.

• DCS520B FLEXVOLT 60V MAX* 6-1/2 in. TRACKSAW
• DWS520K 6-1/2 in. TrackSaw

Notes:

You will want to print this with a material that has some flex as the locking mechanism relies on it. PLA is a poor choice, the model was developed and tested with PETG and I suspect ABS would work great too.