Helix Folding Bike 3D Printed Front Carrier Block

This is a 3D printed Front Carrier Block mounting for the Helix folding bike.

Printed using Bambu Lab P2S with ABS GF, the weight 250g

Print settings:

Outer wall: 8

Infill wall: 3

Infill % : 35

Top and bottom layer:10

The fasteners:

M5x18mm for frame mount (no tapping is required)

M5x30~35mm for Brompton plastic front carrier block (Tapping is required)

I have simulated the stresses using FreeCAD for up to 10KG loading, but cannot guarantee non-invariant behaviour from individual usage.

The design isn't suppose to be printed solid, but the outer wall should be thick, the intuition here is have it function more like a box structure... Think a cylinder with wide diameter and thin wall versus a rod with smaller diameter, the rod weight more and is heavier.

I had use it for commute with a backpack plus skeleton frame total of <7kg, seem to hold up fine, IMO, the M5 bolts onto the bike frame doesn't instil confidence, but I had made consideration with the design, the height being particular tall with the wrap around head stem for support, the weight loading mounting would be better distributed.