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Old 05-20-2014, 12:29 AM   #1 (permalink)
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Default 3D Printed Window Switch Fix

Tired of that broken driver's side window switch?
Why not print your own replacement switch parts?
The files are open source (with attribution):
Insight Window Switch.zip

I initially offered these for sale, but have stopped for three reasons:
-Lack of demand; I've only sold a handful of units.
-I'm not making enough to make it worth my trouble at this low volume.
-Too much customer support. Yes, the dashboard has to come out ... Yes, there's a thread on how to do that. No, I won't walk you through it on the phone. *ahem*.

I stand behind the product I've already shipped, and will warrant those units in the field, if needed; to date, I haven't had a single return for any 3D printed part I offer.

Here's how to install:

There are two design defects in the driver's side window switch:
Spring Detent Body: Terribly designed... I imagine this and the trunk latch mechanism were designed by the same intern.
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The new design is mechanically superior.
-Body thickness increased 30%
-Added a foot that extends down to the PCB; operating the switch now compresses the body, whereas the OEM design experienced shear force (an order of magnitude weaker).

Light Pipe: Also the mechanical linkage that interfaces with the electrical switch.
OEM part is decently designed, except that a light pipe is too brittle to use as a lever, particularly without a hard mechanical stop. The new part is opaque, so the switch will no longer light up at night; VeroClear is the only strong enough clear material and it's only available on high end PolyJet machines... if there's enough demand, we could do a group buy.

Kudos to user Element6 for sending me his broken window switch. Mine isn't actually broken, but I figure this is a fairly common failure that needs fixing.

If you're not comfortable opening up your broken window switch, PM me and we can arrange to ship your entire unit to me; I'll fix it and send it back for $45 (including return shipping CONUS).

Note the feel with 3D printed parts feels softer than OEM - but is still tactile - due to the layering method used in 3D printing. A PolyJet print (group buy) would feel more like OEM, but would also be more expensive.

*You'll likely need a high end 3D printer to resolve these small, dimensionally precise parts. I'm printing drop-in ABS parts on a $30,000 Stratasys SST, but I imagine any machine over $3000 will do a decent job with just a bit of sanding. FYI: Parts printed in PLA won't hold up to the heat/UV.

Last edited by mudder; 12-23-2015 at 03:29 PM.
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Old 05-20-2014, 12:51 AM   #2 (permalink)
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Please post the files/link on the 3d printed parts thread as well.

https://www.insightcentral.net/forums...ght-parts.html

Thanks
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Old 05-21-2014, 01:20 AM   #3 (permalink)
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Quote:
Originally Posted by retepsnikrep View Post
Please post the files/link on the 3d printed parts thread as well.

https://www.insightcentral.net/forums...ght-parts.html

Thanks
Done. Also edited the original post quite a bit and added an install video.
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Old 05-21-2014, 07:11 AM   #4 (permalink)
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Great fix ! Added to my 'maintenance list'.
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Old 06-05-2014, 09:59 AM   #5 (permalink)
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What exactly does this repair? My switch works but doesn't always return to the center off position when I release it. I suspect it causes the circuit breaker to trip since it's activating the motor continuously until I manually center it, and then have to wait a few minutes for the window to work again. Will this part fix that problem?
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Old 06-05-2014, 11:17 AM   #6 (permalink)
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ati:

sounds like yours is already partially broken. My switch returns to center position on its own. If you push your switch too hard now it will fail.
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Old 06-05-2014, 11:35 AM   #7 (permalink)
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That's why I asked what does this fix? And what does $25 shipped CONUS mean? I know FedEx, UPS, DHL, Purolator but never heard of CONUS.
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Old 06-05-2014, 11:40 AM   #8 (permalink)
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CONtinental United States. Probably more $ shipping for UK and such.

(reviewing video again, will repost soon)

At about 2 min or 2:10 in mudders' video, the smaller piece seems to break 1st, which cause too much force to be applied to the larger piece which will break next, rendering the switch inoperative.
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Last edited by Mountain driver; 06-05-2014 at 11:51 AM.
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Old 06-05-2014, 09:55 PM   #9 (permalink)
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Quote:
Originally Posted by atikovi View Post
And what does $25 shipped CONUS mean?

Gov't lingo. OCONUS = Alaska, Hawaii, Canada, Mexico, Europe, etc
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Old 06-05-2014, 10:47 PM   #10 (permalink)
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Quote:
Originally Posted by atikovi View Post
That's why I asked what does this fix?
This fixes the common 'limp' master window switch problem, i.e. the driver's side window switch doesn't return to neutral and flops around. There are two parts that break due to poor design; replacement parts are superior design.
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