Parametric Sanding Block with Heat Set Inserts

Overview

I've designed a parametric sanding block to allow me to quickly create sanding blocks in multiple dimensions to tailor exactly what I need. I've also decided to use heat set inserts/metal bolts rather than printed threads in order to maximize durability (sorry, non soldering iron having people, but get with the program :) ).

BOM

Size of bolt/heat set insert are configurable in the parameters, but to use the pre-made STLs you'll need:

2x M5x6x7mm heat set inserts 

1x 20mm M5 button head bolt

Print Settings

Print all parts as oriented in the model; Below are my recommended settings:

15% infill on the knob and grip; 30% on the base.

4 perimeters on all parts

I've chosen ASA because I wanted a durable tool with increased resistance to temperature and the elements, but PETG would also work just fine. PLA, also works, provided you're not exposing to the elements. 

Parameters

I didn't do a perfect job of naming the parameters, so he's a quick overview of what they do. Note, that there is no error checking, so if you adjust these values in ways that don't make sense, you will have issues in the Fusion 360 design history. 

Sanding Block Model

These values adjust the sanding block model itself.

base_length: how long the block will be, front to back.

base_width: how wide the block will be side to side.

base_height: how tall the base of the sanding block will be (that the sand paper wraps around).

knob_grip_height: height of the knob.

knob_diameter: diameter of the knob. 

base_top_width_variance: how wide the grip is in relation to the base. A variance of 10, for example, will mean that the grip is 10mm more narrow than the base.

tolerance: how much of a gap will be left in the model to account for printing tolerances. Default is 0.2mm.

finish_filet: cosmetic value for how much to round the corners on the model details. 

grip_front_fillet: Adjusts the curve on the front of the block, to contour your hand.

grip_rear_fillet: Adjusts the curve on the rear of the block, to contour your hand.

Hardware

These values tailor the model for the specific hardware you have:

bolt_diameter: should be the diameter of the threaded part of the bolt, plus .4 mm or so. Default is 5.2mm

bolt_head_diameter: diameter of the head of the bolt, +.4 mm or so. (this is so the head will sink into the base).

bolt_head_depth: how far down to sink the head into the base.

bolt_length: used to render the bolt in the model (but does not affect the sanding block model itself.)

heatset_diameter: diameter of the heat set insert, minus about .4mm  to allow more material for the heat set insert to melt in to.

heatset_depth: the height of the heat set insert (exact value).