P80 Volvo 3D Parts Library Build

[ZionXIX]

Hello all,

Ive decided to start a build thread focused on making 3d printed parts for our Volvos. I'm placing this thread in the P80 forum since most of my designs for the foreseeable future will be focused on my 850. I do have an XC90 but shes in mint condition and will not likely need any 3d printed replacements for some time. Progress will be slow and really as I need parts. Currently I have designed inserts for the interior door handles and ECC control knobs.

This first post is going to act as my index and will probably change whenever I make a new post or I edit out irrelevant information.

There are all manner of computer aided design (CAD) programs out there. I mainly focus on Sketchup and Fusion 360 both of which are free. Other popular options are Solid works and Tinkercad. My posts will likely contain Fusion 360 files (.f3d) and maybe a few Sketchup files (.skp). These are original CAD files where you can edit them to your liking. If you just need to print a model then the more common format will be files ready for slicing such as (.stl) files and the newer format (.3mf) files. These are exported models ready for any number of slicing programs. I prefer Cura, others may like Simplify 3D, Prusia Slicer and so forth.

Helpful posts on learning more about 3D printing.

• What is 3D Printing?
• Materials Guide

Index of available designs

• Interior Door Trim Handle Insert
• Volvo 850 ECC Control Knobs

In its simplest form 3d printing is the process of taking a digital 3d model and forming a real world object out of plastic. The process involves using software to "slice" the model horizontally into layers of a specific thickness. Plastic is then heating and squeezed through a nozzle of known size. The nozzle follows a predetermined path decided by the slicing software on how to build the model 1 layer at a time. 3d printing is certainly not perfect and will likely never be as cheap or as strong as injection molded parts. However injection molding has a high initial cost that makes a limited production more expensive. Sometimes it makes more sense to make 1 or 2 objects and 3d printing fills in that need.

Dozens of different materials are available for printing but they have vastly different purposes, properties and attributes. The most common 3d filament used is PLA. Other options may include PETG, ASA, ABS and Nylon filament.

PLA is easy to work with and can produce very clean quality prints. However it does not stand up to heat or UV at all. I do not recommend using this for anything in vehicles unless it's protected from heat and UV light.

PETG is my preferred material for anything going on vehicles. It prints nearly as easily as PLA and can have excellent quality.. This filament has good heat and UV resistance. It's also a bit stronger than PLA.

ABS is another popular materials woth good heat and UV properties but requires a heated chamber and will warp significantly if things are just right. ABS also gives off toxic fumes and should not be printed in the same room as living things. Heat from sunlight inside a vehicle may also release these toxins. I do not recommend this for interior applications. It may have use for exterior parts or engine bay.

ASA is supposed to have good UV resistance and decent strength but I have not used it. Proceed as your own risk.

Nylon has excellent strength and durability but is difficult to print due to its hygroscopic nature. It must be dried before using and kept in an airtight container during the printing process.

[ZionXIX]

Interior Door Handle Inserts

My door handle insert are badly damaged from years of abuse. This is the first volvo part I ever designed and printed. It needs a little fine tuning but it fit my vehicle just fine. Some design changes I made was to do away with the odd metal clips that attach to the underside and usually break. Instead I opted for body style clip for a snap fit with no additional hardware required. The clips made a snug feel and may damaged the fiber board holes a bit. If this is the case I can make them a bit slimmer or you can file the overall size down a bit with some sandpaper or a metal file.

Volvo 850 Door Latch trim.stl

Normal orientation w/o clips

(1.8 MiB) Downloaded 184 times

Volvo 850 Door Latch trim Rotated.stl

Rotated for printing w/o clips

(1.8 MiB) Downloaded 175 times

Volvo 850 Door Latch trim rotated with clips.stl

Rotated for printing w/ clips

(15.45 MiB) Downloaded 183 times

Volvo 850 Door Latch trim.skp

Original Sketchup File

(6.63 MiB) Downloaded 165 times

[ZionXIX]

Control knobs for Electronic Climate Control (ECC).

I seem to be the only one who needs this but my knobs broke at the center and the metal clips popped out. I blame decades of Texas summers. Anyway I designed 2 versions. One that requires the metal clip and one that does not. I tried to mimic the translucent material that lets light through at night. There is a slot with a small recess just for this purpose. At the time of this post I have not found a material I'm happy gluing there yet. I'm looking for an opaque translucent flexible plastic material that can be easily cut and glow with background light behind it.

EEC_KNOB_4_NoClip.stl

ECC knob no clips required

(6.64 MiB) Downloaded 178 times

EEC_KNOB_3.stl

ECC knob, metal clips from the original knob are recommended

(6.67 MiB) Downloaded 150 times

_ECC Knob Volvo 850 Clips.f3d

(299.44 KiB) Downloaded 136 times

_ECC Knob Volvo 850 No Clips.f3d

(392.75 KiB) Downloaded 159 times

[Nevada1906]

This is a really good idea.

I'll be sure to upload whatever I come up with.

[ZionXIX]

Hey Matt, I would like to request another file type for future uploading. One of the newer file types for sharing 3d files is .3MF or 3d manufacturing format. It's supposed to be a lot better and more efficient than STL files. Thanks.

[Nevada1906]

Interior Door Handle Inserts

My door handle insert are badly damaged from years of abuse. This is the first volvo part I ever designed and printed. It needs a little fine tuning but it fit my vehicle just fine. Some design changes I made was to do away with the odd metal clips that attach to the underside and usually break. Instead I opted for body style clip for a snap fit with no additional hardware required. The clips made a snug feel and may damaged the fiber board holes a bit. If this is the case I can make them a bit slimmer or you can file the overall size down a bit with some sandpaper or a metal file.

Volvo 850 Door Latch trim.stl
Volvo 850 Door Latch trim Rotated.stl
Volvo 850 Door Latch trim rotated with clips.stl

Volvo 850 Door Latch trim.skp

DoorLatchTrim.png
DoorLatchTrim2.png

The ones in my car haven't had the locking tabs since I bought it. Friction and gravity's all that're holding them in.

What plastic would you recommend printing these in?
Are they FDM or Resin? Or either?

[ZionXIX]

Interior Door Handle Inserts

The ones in my car haven't had the locking tabs since I bought it. Friction and gravity's all that're holding them in.

What plastic would you recommend printing these in?
Are they FDM or Resin? Or either?

For this I would recommend PETG. I printed the first ones in PLA and unsurprisingly they gave off an awful odor then warped and twisted in the Texas sun. Ive had one of the ECC knobs printed in PETG sitting on a black dashboard for the past week and it shows no sign of heat damage. Another option may be ASA filament for its UV resistance but Ive never used it. I only work with FDM printer. Would love to try Resin but its messy and I dont really have the space for it at the moment. With that being said I have never seen better looking prints than was Resin can achieve.

[Goupil]

Good idea !
I haven't done much 3D design and gave my 3d printer to my mom, but a while ago I made this ring to fix a broken V70 fog light
https://www.thingiverse.com/thing:3619373

[matthew1]

Test .3mf

[matthew1]

Hey Matt, I would like to request another file type for future uploading. One of the newer file types for sharing 3d files is .3MF or 3d manufacturing format. It's supposed to be a lot better and more efficient than STL files. Thanks.

Done.