Many ways to do the same thing … and 3D-Printing added another way to patch a drywall hole left over after removing a Flat-Screen TV.
In the past, I have patched many holes in walls using a plug cut from old drywall or purchased patching material from a hardware store.
Didn’t have any old leftover drywall material to patch the wall, so decided to draw up a 3D-Printed patch while I was relaxing watching TV in the evening.
So this is basically just for fun to see if I could create a patch with 3DP …
The hole was 1.42″ in diameter where the Flat-Screen TV’s cords went through the wall to another room, so used SolidWorks CAD software to design a 3DP solution using Stainless Steel finishing nails.
Once the design was finished I 3D-Printed the two wall hole plug parts …
Tapped No.6-32 Threads in the outer plug’s holes for attaching inner plug …
Tested No.6 screws to connect the two 3D-Printed Plug parts and all fit well.
Next tested placing in 1 nail at a time in the center of the plug and pushing them out as they would go into the sheet rock to secure the plug.
The 3DP Wall Hole Plug can be mounted with 3 nails or 6 nails …
Everything worked in the tests so next step was secure it inside the hole …
Rosie-Cat my SolidWorks Co-Designer fell asleep on the job so was on my own, luckily BKE said she would patch the hole if I would prep the wall.
Just in case, I attached a string to a long screw in the hole plug so it would not fall inside the wall if I pushed it too far, but the fit was tight and it held very well in place about 0.05″ in from the wall to allow space for spackling the area several times for good coverage.
Used all six of the 1″ stainless steel finishing nails about 1/2″ into the drywall.
I could have pressed the nails up to 3/4″ into the drywall but 1/2″ in seemed to secure the plug very well and no need to go deeper and risk drywall cracking.
Screwed on the inner rough finish 3DP part and everything fit well.
With my part finished, BKE took over prepping the wall and finished it.
The area will be sanded, textured, repainted, and artwork put on the wall.
When the artwork is mounted, I will update this post with a photo of it.
The SolidWorks CAD files can be viewed on GrabCAD
Many other ways to do this, but 3D-Printing made it a fun project. 🙂
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