3D Printed Dust Collection Adapters That Actually Fit
Measuring twice, printing thrice, and finally getting a seal.
Shop vac hoses lie about their diameter. What the package calls "2.5 inch" is rarely 2.5 inch when you put a caliper on it.
I measured every port in the shop, modeled adapters in CAD with a 0.2 mm clearance, and printed them in PETG. Three revisions later: a snug push-fit that doesn't whistle.
Print settings that worked
- PETG, 0.2 mm layer height
- 4 walls, 25% gyroid infill
- Brim on the larger flanges
I'll post the STLs once I've used them through a full sheet-goods cutting session. If they crack, revision four gets thicker walls.