Parametric control knob for a D shaft, with a STEP file

The knob every appliance and panel loses. Modeled once as CAD so the customer gets a STEP file and a part that fits the shaft.

The job

Knobs are the most common discontinued plastic part on appliances, test equipment and control panels, and the bore is where they fail. This knob is a parametric family, diameter, height, shaft diameter, flat width, grip scallops, pointer and set screw are all inputs.

The bore is modeled at the size that prints to a snug fit on the shaft. Hole shrink on the printer is size dependent, so the model applies a banded growth measured on calibration coupons rather than a single offset, and the slicer's own hole compensation is left at zero.

Because the knob is built as a solid CAD model, the same file exports a design intent STEP for the customer's records or a machine shop, and a mesh for the printer that passes the same gate as every other part.

Render of a dark grey control knob with grip scallops and a pointer, viewed from an angle
Reference knob, 32 mm, render from the CAD model (not a photograph).
Render of the control knob from the front
Front view, render from the CAD model (not a photograph).

Facts

Shaft6.0 mm D shaft, 5.5 mm across the flat, snug fit
MaterialPETG, 3 walls, 15 percent infill
BoreModeled at 6.27 mm for PETG so it prints to a snug 6.1 mm fit
DeliverablesSTEP file, STL, Bambu Studio project, mesh QA report
ToleranceISO 2768 medium on the bore after first article

What made it work

Small holes shrink far more than large ones. A single compensation number cannot fix a 2 mm and a 10 mm hole at once, so the band table is measured per material.

Model the fit, not the slicer. A part that is right in the file is right in any slicer, which matters when a customer prints a reorder elsewhere.

A STEP from CAD is a deliverable. A STEP wrapped around a mesh is not, and machine shops will reject it.

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