Parametric DC Plug Support using Network Jack

My laptop's DC charger plug sucks. It's tiny 3mm barrel became annoyingly loose after just a few months of use, to the point where even slight movement would make it lose its connection, and it wouldn't take much for it to fall out. The replacement charger I ordered ended up being even worse.

So, I made this and haven't had a problem since!

This model is designed to support your charger plug using the network/ethernet/rj45 jack which is adjacent on Acer Aspire laptops as well as many other brands and models. Unfortunately, every single charger plug is different, so this model is fully parametric - take a few measurements, export, and print. The STL files attached are specific to two of my chargers and likely won't work for you. They are included for demonstration and visualization purposes only.

Currently this version works fantastic with square-bodied DC plugs and not as well with round-bodied ones (although reducing the tolerances a bit might help with that). A previous version worked better with round-bodied plugs and I will likely make some changes in the future to accommodate them better. This model will not work at all with straight plugs, only 90° angled plugs.

If you have an Acer Aspire, you likely don't need to touch the 5 “rj45” parameters - only the “plug” parameters. Plug Boot is the portion of the plug closest to the barrel plug itself, which is typically a smaller diameter than the plug body.

If you have another laptop with a network port next to the charger, there should be enough notes in the model's Spreadsheet to figure out what you need to measure, but if you're not sure, shoot me a message!

Print without generated supports - the model includes supports which are designed to be easier to remove than those generated by a slicer. If you choose to export and print without the included supports, you MUST keep the same orientation (or flip it directly over). If the release lever is not parallel to the layer lines, it will simply snap off.