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Shrouded 4mm banana jack to 24ga silicone wire strain relief 3D Printer File Image 1
Shrouded 4mm banana jack to 24ga silicone wire strain relief 3D Printer File Thumbnail 1

Shrouded 4mm banana jack to 24ga silicone wire strain relief

sixfiveohtwo avatarsixfiveohtwo

February 16, 2025

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Description

This is a strain relief boot for interfacing commonly available inexpensive solderable 4mm banana jacks (e.g. this Amazon listing or this Aliexpress listing) to thinner wire than typical lead wire. The wire I used, 24ga silicone insulated wire, has a nominal overall outer diameter (including insulation) of 1.6mm.

The cylindrical, non-flexible end is intended to slide into the strain relief part of the banana jack shroud and be glued in place using e.g. CA glue.

You may have to use a craft knife or boxcutter to cut any stringing artifacts between the zig-zags in the flexible part of the boot, in case it prevents it from bending fully. Do this before you put the wire in, so you do not nick the insulation.

Print settings:

Filament: TPU (I used Eryone TPU 95A)
Layer height: 0.2mm
Perimeters: at least 2

License:

Creative Commons — Attribution — Share Alike

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