Beer Faucet/Tap Handle w/Card Insert

These 3D printable tap handles are derived (with permission) from those designed by a fellow who calls himself Durhamite on the HomeBrewTalk forums. If you would prefer a really sweet version crafted from hardwood, check him out at HomeBrewedHandles.

I have included several different versions here and you can feel free to modify them (the Sketchup file is included), but please share anything cool you make with the community.

These tap handles are designed to accept a tobacco card sized card sleeve. I print 1.750 inches wide x 2.875 inches tall cards and put them in the sleeve but you could also just print onto card stock and eliminate the sleeves. I've included a couple of cards (Gimp 2 format) as examples.

I initially planned to use brass inserts for the threaded portion, but on a whim I tried printing the threads and it worked well. The best thing is to use a 3/8-16 thread tap (you can get it at most local hardware stores) to clean up the threads after printing. If you do this, it threads onto a tap/faucet beautifully. If you can't use a thread tap, you can actually just use the thread on the faucet or a 3/8-16 bolt to break the threads in, but you run the risk of splitting the print if your layers aren't bonded really well.

You will want to print this using PET (my favorite) or ABS. If you use PLA you will have to keep the sun off of it or it might deform and you will also have to use the thread tap and pray it doesn't crack/split.

The best way I've found to print it is with the back of the tap handle flat on the build plate. You will need to print this with support. I used Simplify3D and I let it auto generate support with a 2mm pillar resolution. You will need to use a small screwdriver and pliers to clean out the support in the threaded area (might not really need support here) and in the slotted area where the card goes. It is a little bit of a pain, but not terrible.

I printed these in PET with the following settings:

0.2 mm resolution
3 walls
3 bottom layers
4 top layers
40% infill

If you're using ABS, I would use 2 bottom layers, 3 top, and 25-30% infill to reduce warping, but this design doesn't seem to warp too badly in ABS.

Prost!