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Oftentimes, we have very expensive equipment and the parts won't stay together because the bosses cracked or damaged. Super glue and epoxy often won't fix the problem at all due to its heavy load and stress around the boss area. How do we repair them? 3D printing the whole part would be time consuming, costly and impossible most of the time.

Step 1: Autodesk Inventor Came to the Rescue

One of the bosses was crushed and beyond repair. Using Autodesk Inventor, I was able to come up with a concept and prototype within one hour. The bottom is a socket the fit in a lower portion of the boss. The top has the new screw hole.

Step 2: 3D Printed Part Installed.

I finished it off by selecting drill bits that closely resemble the original holes If slightly smaller, just wiggle a little bit during the drilling. For safety, I use a table vise to clamp the part while drilling each sides of the holes. I tapped the part down using a small hammer carefully and making sure I don't hit other surfaces.

Step 3: Here Are the Autodesk Inventor and Stl Files.

The Inventor file show how easy is it to create the CAD in Autodesk Inventor. The stl file allow you to make a sample. I positioned upside down (screw hole face down) in Stratasys Mojo and there was no support material required. The part plugged out of the plate with ease and ready to use (no solution dip time required).

I hope you have enjoyed this humble instructable.

Step 4:

<p>Good idea. I have repaired a lot of things using JB Weld to build a new boss and after it cured, drilled it as well. And for most everyone I repaired, the JB Well adhered to the material like it was part of it. I am certain some plastics will not allow that adherence and then maybe some other type repair could be used. Thumbs Up! </p>

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