Summary

When I saw this sanding block I knew I wanted one, but that particular design didn't work well with my FDM printer. I redesigned it and it prints great on my Prusa Mini!

Print Settings

Printer:

Prusa MINI

Rafts:

No

Supports:

No

Resolution:

0.2

Infill:

15

Filament: Hatchbox PETG Black

Notes:

This is printed in Hatchbox PETG. Unfortunately I didn't save my exact settings when I printed it so I'm not 100% sure on the settings. Note that the .3mf file is set for PLA, this print should work in either material.

Post-Printing

Assembly Requirements

To assemble this sanding block you will need 2 M4x20 bolts and 4 M4 nuts. No other post-processing is required before assembly.

M4 bolts with nuts

Add two M4 nuts (one each) to the two M4 bolts. This will prevent the bolts from spinning when we tighten them later.

Sanding block with one bolt inserted, one bolt standing nearby

Insert the bolts up through the bottom of the main body. (This area may be a little messy due to the overhang. That's okay, just clear any mess out enough to get the bolts in.)

Sanding block with one cap inserted, one cap laying nearby

Put the caps into the holes, but don't insert them all the way! Leave a little bit hanging out.

Pressing down on the sanding block to seat caps

Lay the main body on a flat surface and push down. This will push the caps perfectly flush to the bottom of the sanding block.

Bottom view of sanding block, showing caps flush with bottom

The caps are now perfectly flush.

Top view with main body and "holder"

Next, we'll add the "holder". This piece holds the sandpaper strip in place.

Sanding block with holder assembled onto main body

Just slide it down onto the two bolts.

Sanding block with knobs and 2 M4 nuts

Next you'll need the two knobs and two M4 nuts

Nuts placed in the knobs

Place the nuts in the knobs, then screw them onto the bolts. Leave them loose at this point, so you can insert the sandpaper.

Knobs placed on bolts, sandpaper strip nearby

Cut a strip of sandpaper 1 inch wide. The sheets I had happened to be the perfect length, but you may need to trim yours to fit.

Fully assembled sanding block

Slide the sandpaper in between the pieces, hold it taut, and tighten the knobs. You're ready to sand!

Small Sanding Block