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I made a CAD model, did some tests to see what would work and built this desk. It's called \u2018Carl\u2019s Desk', because the original was made for Carl.

This is a rebuild for the print tables contest, the 3D printed parts are now orange so they stand out, but you know\u2026 It looks great so I'm keeping the orange!

The connectors

Printed with 100% infill, the print orientation and settings I used are shown in the included print files.

I originally designed the nut connector as a compression fitting that would expand to push against the tube as the nut was tightened. This design did work but I found a simple friction fit connector knocked in with a rubber mallet to be just as effective as the compression design.

As the nut was no longer needed to compress the fitting, I moved it closer to the joint, so I could use shorter screws. Doing this also appeared to make the joint more stable.

The desk frame

25mm Square Steel Tube with a 1.2mm wall, the connectors friction fit in the tube and hold an M8 Nut, the connectors are oversized by 0.4mm internally for the friction fit to work. Holding the nut in place is achieved by a small feature in the part; once the nut is fully seated it will stay in place.

Stability and Strength

The frame is surprisingly stable on its own, with the addition of the shelf, desk-top and vertical cable tidy board below the desk-top at the back, the thing is solid. It appears to be able to hold a fair bit of weight but I have not done any measured tests yet.

As this is a redesign, strength and rigidity have been improved over the original design. This was in regular use for just under two years, with no issues. (The last picture in the reel above is of the original desk, in which the 3D printed parts are Black PETG.)

Building the Desk

Bill of Materials

500g PETG Filament

25mm Square Steel Tube 1.2mm Wall
2 x 150mm (Top a-frame link)
2 x 550mm (Bottom a-frame link)
2 x 1833mm (Front Leg)
2 x 1770mm (Back Leg)
5 x 1190mm (Cross Support)

14 x M8 Hex Nut, 13mm between hex faces, 6.5mm tall, A2 Stainless
14 x M8x45 Button Socket Cap Setscrews, A2 Stainless
14 x M8 Washer, 8.4 mm ID, 16 mm OD A2 Stainless
15 x 5.0x35 Countersunk Wood Screws.
1 x Desk-top, 18mm OSB, cut to 650mm x 1200mm.
1 x Shelf-top, 18mm OSB, cut to 306mm x 1200mm.
1 x Cable tidy board, 18mm OSB, cut to 200mm x 1200mm.

Tools and Consumables

`Angle Grinder - with some Cutting discs + 120grit or similar Flap Sanding Disc`
`Combi Drill - With Drill Bits For Steel 1.5-10mm set`
`Tape Measure`
`Speed Square`
`Centre Punch + cutting oil`
`Masking Tape`
`Pencil/Sharpie`
`Screwdriver with 5mm Hex bit and PH2 for the wood screws`
`Rubber Mallet`
`Paint for the steel Tube`

The Build Guide

Before I go any further, work safely and measure as carefully as possible.

This is a fairly basic build guide, if you're unsure of anything, I suggest using the comments or asking a local maker/fabricator.

These instructions may change, there are probably some minor mistakes, but they'll get you there, unsure of anything, please ask in the comments. - AM

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