Cutler-Hammer Circuit Breaker Blanks

Backstory

I kept seeing my circuit breakers with all the gaps/holes each time I did my laundry.  I couldn't find an existing breaker size that fit my particular set of breakers.

I designed this from scratch in Alibre Design Pro, with some slight inspiration from a couple of other models (to see how best to make it snap in).  I didn't remix any of the others, though, and made my own decisions on angles/sizing.

Print Recommendations

I printed mine in PLA since it didn't have many requirements for heat, UV, rigidity, etc.  I used gyroid infill and found even 5% to 10% infill worked fine enough. Print with the face flat on the bed.  It is a reasonably easy print without many problems, so no support is required.

Hardware/Assembly Information

They are relatively easy to pop in and pop out. I recommend measuring your gaps to see what combination of the blanks you may need, mine had a lot of wide gaps between them, so I had to do a couple of different sizes to fill in the puzzle that is my breaker box.  My box is from the 80s (most likely), so possibly newer models might not fit as well if any significant changes were made.

Usage Recommendations

All the blanks are 61 mm Long and 3 mm Thick, with around 6 mm additional for the legs that stick out.  These are the dimensions that may help you with figuring out which parts to use:

Half Blank - 8.25 mm Wide

Single Blank - 16.5 mm Wide

Double Blank - 33 mm Wide