Aluminium Extrusion Nuts and T-Nuts

Updated Version to my previous design. (simplified the design and edited some geometry to make them fit universally)

A set of easy to print and use nuts for 20-Series and 30-Series extrusions. 

There are 2 types and 3 mounting options: Normal slide-in nuts and T-nuts using Heat-Set inserts, Hexnuts and undersized holes to directly screw into.

As the name states, you can choose the ones you need and what hardware you have around.

BEFORE YOU PRINT:   Please measure the slot width of your aluminium extrusions to determine which set of inserts you need.

There are narrow and wide slots on both the 20-Series and 30-Series extrusions. Make sure to select the right files.

Some sizes are not fesable due to minimal wall thickness and strength requirements, , thus I did not add them.

I personally recommend the ones with the Heat-Set inserts. They are the most durable ones and perform reliably.

Printable in pretty much any plastic except flex, whilst PC is propably the best option. Since the parts are so small a 0.4mm nozzle and 100% infill is a must. Max. 0.2mm layer heigth.

Please check the required hole diameter for your insert before printing the part. I used the Ruthex brand, CNC citchen has the same sizing.

M2.5, M3: 4.0mm

M4: 5.6mm

Whilst most look similar, they can require diferent sizing. I added  .f3d files of the blank nuts to edit if needed.

Please check the length of your inserts. The max length for the 20-Seriees nut is 4.5mm and for the 30-Series nut is 6mm.

If you do not have short enough inserts, you can also dremel off the last rib from the normal sized ones. This worked fine for me.

To install the inserts use minimal heat to prevent deformation of the thin throat at the top. 

To prevent issus when installing in the extrusion, let it cool down after insertion and run a screw or tap trough the threads to clear the hole. If the bootom bulges a bit, use a knife, file or sandpaper the remove excess material

The Hexnut variants of the T-Slot nuts require support material. To remove the support material, simply push it out with a screw. The nuts are designed to be press-fitted into the plastic. If it does not hold too well for you, might consider using a small drop of glue to keep them in.

Feel free to comment or contact me if you have any suggestions for more specialized nuts or other sizes.