Strength problems with small mounting "pegs" for large battery charger mounts
I have designed some battery holders for Toro 60V and Echo 56V chargers for Multiboard, attempting to minimize wobble, so I have had to make things pretty tight. Both of these chargers are quite large and with a battery inserted, quite heavy.
Both of these chargers have a design where the top hole is vertical and the bottom hole is horizontal, requiring you to attach the top hole and then swing the bottom hole onto the bottom peg at an arc.
In any case, the little pegs keep breaking off, since they experience different kinds of force depending on whether you are performing the one time installation (Shear & Rotational), or inserting and removing the battery repeatedly (Shear).
I have tried PLA, PETG, and ASA on my X1C, and PETG so far seems to be the most promising. Here are some of the settings I have adjusted in an attempt to make the pegs stronger, but they still will break eventually. I am hoping someone can help point me in the right direction, even if that means trying other filaments.
Override Settings
Layer Height: 0.08
Wall Loops: from 3 up to 10
Sparse Infill: 90% with Gyroid pattern
Main Printer Settings
Printer Model: Bambu Lab X1C
Slicer used: Bambu Studio
Filament Bambu Lab PLA Matte, PETG Translucent, ASA
Nozzle and bed temperature:
PLA Nozzle 220C (Default)
PLA Bed 55C (Default)
PETG Nozzle 250C (Default)
PETG Bed 70C (Default)
ASA Nozzle 270C (Default)
ASA Bed 100C (Default)
Print Speed: 50/105 (Default)
Retraction settings: 0.3mm for PETG, N/A for PLA & ASA
Posted Dec 29, 2025, 8:01 PM UTC