A Mechanical Freelancing Hub

The requestor needs a clean, watertight 3D CAD model of a sliding joint cap that fits precisely into a specified aluminium channel for a DIY project. The part will be 3D-printed in PETG, so the design must respect PETG-friendly wall thicknesses, radii and shrinkage, and allow a reliable sliding fit with the supplied channel profile. Exact dimensions, tolerances and the mating channel section will be supplied as a hand sketch; you’ll also provide an existing STL of a trial cap for fit verification.

Deliverables & scope:

Produce a parametric CAD part (STEP or native Fusion/SolidWorks) and a print-optimized STL that preserves the fit and feature fidelity for PETG. The model will be designed with recommended PETG walls (1.5–2.5 mm typical), chamfers/radiused corners, and a suggested sliding clearance (nominal 0.2–0.5 mm depending on your channel tolerance) so the cap inserts smoothly without wobble. Final deliverables: (1) STEP (or native) CAD file, (2) final STL optimized and manifold for PETG printing, and (3) a short note with suggested print settings (recommended layer height 0.15–0.25 mm, 20–30% infill, and orientation/support advice) so you can reproduce the fit on your printer.