Corner Blocks

This customizable corner connector is designed for 90° joints between Aluminum Extrusions (T track, V track, 8020, 1010, 1515, 2020, 3030, 4040, etc.) Also, the connector can be used to join flat surfaces, by specifying no tab on one (or both) edges.

The tabs can be sized to fit appropriately snugly in the extrusion channel.

The optional counterbores allow you to inset your fastener heads. I find Phillips Round Head screws and Hex Socket Cap screws have worked well. You can size the counterbore to allow a washer between the screw head and the connector.

There is an option to print the connector with the diagonal side on the build plate. This can have two advantages: No supports are needed for the tabs. Also, the extruded strands of filament run diagonally across the joint which should add a bit of additional strength to the finished bracket.

Related Things:
Aluminum Profile Nut Holder https://www.thingiverse.com/thing:5139044
Aluminum Profile Flat Corner Plate https://www.thingiverse.com/thing:5139529

Design and Printing considerations:

The only design Gotcha I have encountered is that you have to do a bit of planning for locating the fastener holes/counterbores closest to the corner so that the heads of the fasteners do not collide.

I have had success printing the connectors from PETG, but any type of appropriately rigid filament should work.

[Thingiverse Customizer sometimes seems to refuse to run. (It probably takes a lot of computer resources to Customize files for everyone in the world.) A workaround is to download the OpenSCAD application and process the .scad file on your own machine. I have posted a brief guide. http://bit.ly/openscad-at-home]