3 Ways to Fix a Frayed Charging Cable

Not only is it annoying to have a frayed charger, but it can also be dangerous. In this Instructable, I will show you 3 ways to fix or protect a broken charger. Let's get started!

Step 1: Method 1: Heat Shrink Tubing

Using Heat shrink tubing is an easy, cheap, and effective way to fix, repair, or protect your cables from harm. I recommend this method for serious fraying or need for protection. This method only needs two external materials, here is what you will need...

What You Will Need:

- Heat Shrink Tubing

- A Heat Source (ex. Hair Dryer, Heat Gun, Lighter,...)

- Your Charger

Step 2: Cutting the Tubing

The size tube you will need depends on the charger you need to fix. For the apple lightning charger, I used 5/16" tubing.

Cut a piece of your heat shrink tubing. You should cut a piece big enough to cover a small piece of the charger top and then until the frayed part is fully enclosed

Step 3: Shrinkin' It

Using a heat source, I used a lighter, carefully hold the flame close to the tubing until you see it start to shrink. Be sure to move the heat or flame to prevent burning.

Step 4: Method 2: Silicone Putty

This method for fixing cables is probably the most protective and provides the fixed cable with lots of flexibility. Here is what you need to make your own silicone putty:

What You Need:

- 100% Silicone Caulk ( https://www.amazon.com/Gorilla-Percent-Silicone-Se... )

- Cornstarch

- Gloves

- Mixing Stick

Step 5: Making the Silicone Putty

Put your gloves on now before starting.

This kind of silicone has a strong vinegary smell that may sting your nose. Do this in a well-ventilated area or outside.

Squeeze a blob of silicone into the plate of cornstarch(about 1 Tablespoon). Then cover the silicone with cornstarch and start to mix them together. Don't be afraid of adding too much cornstarch. Proceed to kneed the silicone adding cornstarch until it is not sticky. Now lets mold this around our charger!

Step 6: Molding Around the Charger

*Keep in mind that you should have 10 -15 minutes to work with the putty before it sets.*

After your putty is made flatten it into a thin strip and wrap it around the charger. You can use your hands to roll it into a log. Then If you want you can use a straight edge to sharpen the edges. You can mold it into any desired shape as long as the frayed part is protected. Keep in mind that after the putty sets into a rubber you can also shave it away with a knife or vegetable peeler. This method is great because of the flexibility that the putty offers. :)

Step 7: Method 3: 3D Printing

In this method, we will use 3D printing to create a protective shell around the charger. Autodesk's Fusion 360 is a great tool to design models for 3D printing. Also, it is free for students! You can design your own model or use mine. If you don't have a 3D printer don't worry! Check your local library or school. Most libraries are investing in 3D printers. My printer was broken so I got it printed at the library. This is a great cheap and effective way to fix your chargers. Let's get printing!

* You will need to print two of the model provided*

Here is where you can download Fusion 360: https://www.autodesk.com/products/fusion-360/stude...

Step 8: Preparing and Printing the Model

It isn't too hard to prepare this model for printing. I recommend PLA filament but If your printer is capable of printing ABS well then that would work even better. Here are the print settings:

Print Settings:

Layer Hight: 0.1 mm

Speed: Slow, 25 - 40mm/s

Infill: 100%

Supports: None

Raft: Optional (but Recommended)

*Other settings depend on the printer being used*

if you own a 3D printer then to print the model upload the file to the printer and start printing!

I also recommend 3D Hubs a Service that will professionally print the part and send it to you. Here is their website: https://www.3dhubs.com/?campaignid=1532912537&adgr...

*this option may cost extra due to shipping charges*

Now that the parts are printed let's assemble everything!

Step 9: Assembling the Printed Parts

To assemble the parts all you need is super glue.

Start with putting the glue into one of the halves of the cover. Then press the charger in and hold firmly for 30 seconds or until connected.

Repeat with the other half. Add glue on to the outside where you may see some cracks just to hold everything more firmly.

After that just give the glue a few to set and you're done!

Thanks for reading this instructable and I hope that it will be helpful for all of you that need it! If you have a question don't hesitate to ask!

- Nathan

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