Design: printed threads with an outer clamp collar can integrate a locking spline into the thread by partially padding and pocketing through the thread in CAD

This system can be adjusted and securely locked in place. This example is a M42 2mmp. A printed tool fits the clamp collar outer spline to adjust tension on a bicycle crank while the base is attached to the crank spindle.

Also, this is ABS (Polymaker) after sanding and polishing. ABS (and ASA) sands and polishes extremely well taking a polish better than any other filament I have tried. Polishing maintains/improves structural integrity without needing extensive measures to offgas like with acetone.

https://lemmy.world/pictrs/image/14b3b6ce-39b5-4bdf-be15-8f5099392f4b.jpeg

Prusament PC blend is the strongest and longest lasting material I have tested in this application. While you will not be able to see this in the pic, when PC is polished it still maintains tiny imperfect inclusion lines that are from the printing process. These do not go away if the extrusion temperature is increased and they are not limited to extrusion line boundaries. They are present throughout, are smaller than a human hair, and only directly noticeable upon very close inspection.

While I am partially disabled from a broken neck 9 years ago, on a road bike the damaged area is neutral. I am a former amateur racer and a clydesdale of a cyclist. The only time of the day I can really fake being normal is on a bike, and I never lost my race legs. I only mention it because it should paint a picture of what is possible with prints like this and what this part has held up to. I have tested dozens of design iterations over the last 2 years and most filaments in this project just to see how they hold up.

Hopefully you find design ideas interesting like I do, and this gets you thinking. If so, please share similar types of ideas and discoveries.