40mm Radius Aluminium Profile End Cap (3D Printable + Open Source)

🧩 Description

This is a custom end cap designed to fit a 40 mm radius aluminium profile.
It provides a clean, professional finish to the end of the curved section while protecting the aluminium edge from knocks, dirt, and debris.

The model was created from scratch to match the contour of the extrusion precisely, with small locating pegs that snap into the channel for a snug and secure fit.

This version prints easily, fits perfectly, and can be modified to suit your own designs.

📦 Included Files

STL file – ready to 3D print

STEP file (End Cap) – for editing, customisation, or remodelling

STEP file (Aluminium Profile) – a reference model for designing compatible parts

⚙️ Printing Recommendations

Material: PLA, PETG, or ABS

Layer height: 0.2 mm

Infill: 20–30% (or solid if you want extra durability)

Supports: Not required

Orientation: Print flat on the back surface for best results

🔧 Notes

The locating pegs are designed with standard FDM tolerances in mind; if your fit is too tight, lightly sand the pegs or scale the model up by 0.5–1%.

Feel free to remix, adapt, and share your versions — this project is released under an open-source license to encourage modification and improvement.