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This model offers an alternative to standard, screwdriver-shaped handles. It uses the same parametric model from my hand drill, but with modifications for a hexagon hole. After gathering several drivers here in the USA (both name brand and budget-bin specials) I consistently measured 6.3 mm across the parallel sides of the hex.

Revision 2

I updated the design to use socket head cap screws and square nuts. Button head screws will still work of course. With more practice, I also improved the CAD file. It is much harder to break any of the operations. Screw length now determines the handle thickness, and I double check that the handle length is sufficient.

I also added a feature to lock a bit driver in place using the small rounded section near the end of the shaft. In case this shape is not universal I also include models without it.

Supplies

You will need:

(5) M3 square nuts (DIN 562)
- or (5) M3x5x4 heat set inserts
(5) M3x12 SHCS

Clamping & Tolerances

I modeled for several tolerances to make sure you can have a wobble-free fit. Similar to the drill handle, the tolerance needed a small adjustment to get enough clamping pressure. (In the parametric design file, the user parameter \u201chex_tol\u201d has a -0.15 mm adjustment.)

Normally print with tolerance	File set
0.14 mm	Tight
0.22 mm	Standard
0.30 mm	Loose
Custom	step, f3d

Notes

I recommend using a 0.1 mm layer height and 0.4 mm nozzle diameter for the best success. I used 0.24 mm for the first layer, but this should not have a large effect.

If you want to make a custom size hexagon hole, I have included a step file. Use your favorite CAD to extrude the hole. If you want an entirely custom handle or other modification, I include the f3d file with design history. The primary design elements have user parameters.

Minor update: I reorganized the downloads so that individual parts are separated into their own file, and compatible parts are bundled together into a zip file. I still include stl and step files.

Minor update: Updated pictures.

Thanks for visiting, and enjoy!

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I remixed my own design to fit a magnetic hex bit driver.

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