3D Printed DIY AC Power Grommet

It would be quite useful to have one or two power sockets on the table to charge devices something like a laptop or smartphones.

This project doesn't require much support from different tools. In terms of tools 2 things are mandatory:

• 3D Printer
• Phillips Head Screw Driver

Requirement For This Project:

• 1 X AC Socket
• 3 X 0.5sqmm 1.5 Meters Wires (I am preferring Red, Black & Blue)

Everything is explained in the video below. First of all, Watch it carefully.

First of all, you have to measure the cutout of the table where the AC Power Grommet will enter. This measurement is important. in my design I am not adding any nuts on the back to hold the grommet in place. So, I have to make this grommet as much tight as possible because while removing the plug from the grommet I don’t want that the power grommet also removes from the table. 

Obviously the the main component of this project is the socket. After disassembling the back of it we get three individual pins where the plugs actually make contact. These 3 pins and this outer shell are important for my project.

To keep all of the measurements in mind I have designed my own desk power grommet in Fusion 360. It also has a lid on the back for safety. Also, we have to carefully measure the dimension of each pin of a 6A D-type plug and their in-between distances which are more or less something like 12.73mm.

After exporting the model into the slicer I need to change 5 major settings. Layer height which should be 0.25mm, print pattern Gyroid, temperature: for the nozzle and bed 220 degrees Celsius and 60 degrees respectively, Print speed: 120mm/s would be enough, and finally Infill density which represents the strength of the print - I choose 55% infill. That’s it. Let’s slice it and move the GCode to the printer. By the way, I have used PLA to print all the parts.

Also need two spacers. Watch the video to understand why.

Now, it’s time for Assembling, first of all, I have inserted the spacers on top of the unnecessary holes and used a bit of two-component adhesive on them.

Next, I have placed the pins on their respective cutouts and put the socket’s back cover in place. That’s possible because in design I have left grooves so that the piece can easily slide into.

As with the design, I have left a screw hole on the body so that I can easily use a screw to mount the socket on the back – not too tight not too loose.

All the project files...

While that is done I have prepared the extension wires. I have picked 0.5sqmm red, black and blue respectively for phase neutral and earth. I need 1.5 meter of them. After stripping them off I have hooked them up accordingly. The right side from the front is phase so from the back left side is the phase, the right side is neutral and the thick one is for earth.

Next, what’s mandatory is to connect a suitable plug top. This is the wiring scheme that I am going to follow. Right side is phase left is neutral and this big one is for earth. The wiring is completed.

All we have to do is to set it in the desk cutout and the back plate for safety. So, I have passed the plug through the hole and set the grommet with a lot of pressure. Finally, I have set the back cover of the AC power Grommet with super glue.

I have charged my laptop with this AC power grommet without any problem.