My wire straightener project was focused on simplicity and reliability. There are no mechanical adjustments for different gauge wires or to correct for a 3D printer's dimensional accuracy (or lack thereof.) Every adjustment had to be made in CAD by changing the relevant dimensions and printing a test unit. This requires more work up front, but once all the dimensions are dialed in, the single piece tool will never fall apart and will never need readjustment.

It also means the raw STL files generated by Onshape for my printer would probably not work properly for anyone else. For starters, it was tailored for my specific spool of 18 gauge copper wire. According to Google, 18 gauge translates to a diameter of 1.02mm. My calipers say my spool is 1.00 +/- 0.01 mm, slightly smaller than specified. It is then processed into G-Code by Simplify3D, my printing slicer. And finally that G-Code is translated into plastic by my printer, with all its individual quirks.

So while I was happy to share my Onshape CAD file, I resisted sharing the STL because it almost certainly would not work correctly and I don't want people to have a bad experience with my design. But people ask for it anyway, over and over.

I have since changed my mind on the topic of posting the STL. I will post the STL, but never by itself. I will also post information describing why the STL is probably not going to work, link to Onshape CAD, and what people need to do to make their own. I foresee the following possibilities:

1. People who don't read the instructions will print the file as-is:
   • If it works for them - great!
   • If it doesn't:
     • Abandon with "This design is stupid and it sucks." - Well, let's face it, I was not going to reach this audience anyway.
     • "Maybe I should go back and read the instructions."
2. People who read the instructions:
   • Successfully fine-tune parameters to successfully make their own straightener - great!
   • Tried to follow directions, but encountered problems and need help - I'm happy to help.

Unless I've failed to consider something horrible, these possibilities have more upsides than downsides, so let's try it. I'm going to share the STL files on this project page, and I've created a Thingiverse page for it as well.

(Cross-posted to NewScrewdriver.com)