Instructables

How to repair a Bugaboo Pram with 3D Printing

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Pram connoisseurs out there will know that the Bugaboo is by far the best pram on the market for style, function, ergonomics and collapse ability, unfortunately they are also very expensive to buy and even more expensive to repair, until now.... 

With the increased accessibility of high quality 3D printing thanks to Shapeways, you can get your Bugaboo back on the road for $25, not bad considering I was quoted $250 for a repair.....

Following is a step by step guide to repairing the handle lock, without which the pram is near useless.

I 3D printed my replacement parts in stainless steel using Shapeways, you could try ABS and do it much cheaper but I really recommend stainless steel.
 
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Step 1: Pry Off That Hub Cap

Picture of Pry Off That Hub Cap
Ok the first step in creation is destruction.
You need to pry off the hub cap to get access to the broken part.
I would recommend using 2 flathead screwdrivers, but a swiss army knife and a bottle opener will do the job,
Take care not to transform the surrounding plastic into a gnarled mess, the wife will appreciate that.

Step 2: Open that baby up

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Bugaboo_repair_with_Shapeways_3D_printing-07.JPG
Inside you will see a plastic hub and 2 steel pins.
In my case it was the steel pins that broke, in other cases it is the plastic hub.
If your plastic hub is broken you may need to measure and 3D model to 3D print that component.
If  if it is broken steel you got.  3D print your replacement parts from Shapeways in stainless steel .
They should cost you around $11 each

Step 3: 3D Printed Awesome from Shapeways

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Once your bugaboo replacement part arrives from Shapeways you are ready to rock.

Step 4: Fit that part

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OK, the 3D printed part can only fit in one way, so do that.
Easy....

Step 5: Re Assemble

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Squeeze the hub back together

Step 6: Now REALLY squeeze it back together

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this makes it possible to refit the hub cap

Step 7: Jam that baby on

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Some people would use a mallet, or perhaps a hammer with a soft cloth, others their forehead but I choose to hammer the cap back on with my manly hands.

Step 8: Ta-Da

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With under $25 worth of 3D printing you have saved $225 worth of repair bills to get your Bugaboo back on the road/footpath/sidewalk/mall.
vic550211 months ago

oh and the website is www.prelovedbugz.co.uk

vic550211 months ago

or if you cant be bothered to do it yourself! (or just have to left hands like myself - just could not fix this at all

prelovedbugz via ebay

spoke to a lady called hannah who does the repairs herself, mine cost £50 and that was including her arranging it to be picked up and returned to me

no extra charge for parts

she was really nice, and helpful on the phone... alot more personal than using a bigger company (and kinder on the wallet!)

well i would recommend her - she put me to shame!

stewhall2 years ago
The stainless ones on eBay that are waterjetcut are cheaper than shapeways and were actually manufactured 1st but also the integrity is guaranteed over 400 have been sold now
fred272 years ago
Brilliant. I've got one of these prams and the handle lock is fairly loose. I'm going to favourite this because it's bound to break soon. I'm tempted to take it apart and have a look, but you know that'll probably make it worse.
fred27 fred272 years ago
I should probably add that I've got a small CNC mill and some chunks of aluminium lying around, so would probably mill one myself from your design.
OH2BIO3 years ago

If I were factory supervisor, I would send these (obviously cheaply made) parts for free to the customer who has ability to do the job himself. Anyway, your fix is better and you have made an interesting job.

BTW: eBay has two sellers selling these in UK. Other one is made of stainless steel and the other one of hardened aluminium. Seller of the aluminium ones says that he has f ixed over hundred prams last year! What on Earth!
caitlinsdad3 years ago
Was there a safety recall on that part? For such an expensive carriage, I would think you could get warranty service or at least order the part since you took it apart. I think if it is determined that it is defective design causing the part to break, the manufacturer would want to know about it and remedy the situation immediately being the business they are in.

Be aware that replacing metal parts with another metal part in a critical application you have to know that the structural properties are the same or exceed the specs of the original part.
dscott4 (author)  caitlinsdad3 years ago
The response from Bugaboo was VERY slow and they only replied after 3 emails. The closest authorized repair center is around 900 miles away from where I live (In Australia) so I would have to send to get a full quote, at my expense... I had read around online and there seemed to be a lack of support post warranty.
The material I used to 3D print with Shapeways is 420 Stainless steel which is really quite strong .
http://www.azom.com/article.aspx?ArticleID=972

There is a far greater likelihood of the small plastic pins that the steel component locks into failing before the stainless steel would.
The Shapeways 420 stainless looks like an interesting material. According to the specs, it has properties comparable to normal stainless (EDIT-not exactly comparable, but quite decent). I couldn't tell from the original picture if your original part was stamped or cast alloy or something else, but the shapeways part looks quite adequate as a replacement.

That being said, as per caitlinsdad, you have to watch out anytime you are changing materials, especially if it were a more critical application. 3D printing is awesome, but people need to be aware that sintered materials do not behave the same way as other metals, for example rolled steel, and more importantly, they don't fail in the same way. Sometimes, hard or rigid metal parts are good, sometimes it's the opposite of what you want.
Yeah, I was thinking the same thing re:replacing a metal part with an (inherently brittle) sintered part, but looking closely at the original pieces, it is almost certain they were some garbage zinc-alloy or aluminum castings anyway...
Joseph Lau3 years ago
I just geeked ... this is awesome!
mhayes53 years ago
For this type of work, I would recommend Alibre Design. They have a free version and it is very good for designing precise solid parts at a fraction on the cost of Solidworks.
rrwood3 years ago
I take it that you designed the replacement part yourself before ordering from Shapeways, right? Any comment on how difficult that was?
dscott4 (author)  rrwood3 years ago
I have a background in industrial design so the CAD part was very easy for me.

If you do not have CAD skills you could even trace it in Illustrator and use the Shapeways Image Popper to extrude it to the right depth.

http://www.shapeways.com/blog/archives/816-Introducing-Image-Popper,-a-new-way-to-easily-3D-model-and-3D-print.html

The only slightly tricky part was getting the angle and radius right, but modeling and printing (on paper) 1:1 to check made me fairly confident...
rrwood dscott43 years ago
Interesting!

I do some work for a Wired Magazine blog called GeekDad. Would you be interested in doing a short interview for a posting? If so, get in touch with me as roy-at-geekdad-dot-com (you know how to parse that ;-) ).

Proof of identity is here:

http://www.wired.com/geekdad/author/rrwood/
dscott4 (author)  rrwood3 years ago
Cool, email sent..
This is great. What software did you use to model the piece?
dscott4 (author)  fungus amungus3 years ago
I used Solidworks, but you could just as easily use Autodesk 123D or SketchUp which are both free,..

The STL file is available to download if you want to tweak or print at home?

The tricky bit was measuring the angle off of the curve and the radius off of the angle.