DIY Drywall Hole Saw (66mm) - 10mm Shank - Reinforced

This is a functional 3D printable tool designed for light-duty electrical installations in drywall (gypsum board). It is optimized for 66mm standard mounting boxes. While it cannot replace a bi-metal hole saw for professional daily use, it is a perfect emergency tool or a low-cost solution for a few DIY holes.
📐 Technical Specifications (Realistic Data):

Hole Diameter: 66 mm (Standard for EU electrical back boxes).

Shank Diameter: 10 mm (Fits all standard 10mm and 13mm drill chucks).

Center Pilot: 6 mm with internal reinforcement gussets to ensure stability during the initial cut.

Tooth Count: 36 aggressive teeth designed to "scrape" the gypsum rather than melt it.

Debris Management: 3 large ejection ports to prevent the fine gypsum powder from clogging the tool.

🖨️ Mandatory Print Settings (For Safety & Strength):

Infill: 100% Solid (Mandatory). Anything less will cause the shank to twist off under torque.

Material: PETG or ABS/ASA only.

    Why? PLA is too brittle and will shatter. PETG has the necessary "flex" to handle the torque, while ABS has better heat resistance.

Walls: 10+ Wall Lines. This ensures the 10mm shank is a solid block of plastic.

Layer Height: 0.2 mm.

Cooling: Minimum fan speed to ensure maximum interlayer adhesion (strength).

⚠️ Reality Check & Usage Instructions:

Consumable Tool: Expect the teeth to wear down after 3–5 holes. This is a plastic tool cutting an abrasive mineral (gypsum).

Low Speed (RPM): Use your drill on the lowest speed setting. High speed = Friction = Melted plastic. If you see smoke or smell melting plastic, you are going too fast!

No Hammer Mode: Ensure your drill is in "Drill" mode, NOT "Hammer/Impact" mode. Impact will shatter the printed structure instantly.

Pressure: Apply light, steady pressure. Let the teeth do the work.

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