# Rocker Switch Cap

A Contura style rocker actuator that clips onto the switch body's pivot pins. Pick the face, the rocker action and a label, then print one cap, a batch or a tolerance test set.

[Open the configurator](index.html) · status: **draft**, version 0.6.2

The cap has a face on top, a pivot leg on each side with a hole that snaps over the switch pin, and a cam under the face that rides the switch plunger. Labels go into the face as a flush inlay in a second color, a raised label or an engraving.

## Where the Contura numbers come from

The **Carling Contura II** preset comes from Carling's own STEP model (Contura II, 8 terminal, from carlingtech.com/elibrary), measured in the browser:

| Feature | Value | Source |
|---|---|---|
| Face | about 36.5 x 21.8 mm | STEP, actuator outline |
| Pivot pin | 3.56 mm (0.140 in) | STEP, cylinder on the pivot axis |
| Pivot hole in the OEM cap | 3.81 mm (0.150 in) | STEP |
| Pivot axis to top of face | 6.9 mm | STEP |
| Bezel | about 49.8 x 23.9 mm | STEP |
| Pivot span, pivot height, cam depth, travel | estimates | not separable in the merged STEP solid |

Measure the estimates on a real switch with calipers before a final print. The tolerance set finds the clearance for your printer.

## Settings

- **Face**: style (flat, curved crown, thumb dish, half rocker), length, width, crown height, dish depth, pivot to face, corner radius.
- **Rocker action**: ON-OFF (V cam), ON-OFF-ON (center detent and a face line), momentary (ramp cam); travel each side, plunger contact offset and depth, cam size.
- **Pivot and fit**: pin diameter, hole clearance (-0.10 to +0.30 mm, default +0.10, added to the diameter), pivot wall span and thickness, pivot height, leg length, round hole or slot with a snap lip, and per leg teardrop holes and lead in chamfers.
- **Label**: text (one or two lines, five fonts including the 14 segment font), an icon (light, fan, fridge, heater, USB, outlet, solar, battery, water, garage, power) or an uploaded SVG; position (top half, bottom half, centered, both halves); method (inlaid flush, raised, engraved) and depth (0.4 mm default); label color.
- **Switch body and lighting**: pick the Carling body. Each shows its bare part number and the number with a stock cap. A lit body adds the backlit window method, a window filament, an indicator window (bar, dot or line 2 text), the lamp distance from the pivot, and two preview switches: backlight on and switch on. The preview shows the LED color as it looks through the window filament.
- **Batch and test set**: a list of caps, one row each with its own text or icon, exported on one plate. The tolerance set exports five caps from -0.10 to +0.10 mm around the current clearance, each marked with its number.
- **Shell**: face thickness, skirt wall, skirt depth.

## Filaments

The Filament panel has three choices:

- **Face filament**: ASA (default), PETG HF or PET-CF, with your Bambuddy spools first.
- **Label filament**: the same as the face, or ASA, PETG HF, PETG Translucent or PET-CF. Backlit windows need PETG Translucent. ASA and PETG do not bond well; the page warns.
- **Support filament**: the same as the face, Support for PLA/PETG, PVA, Support for ABS (not in your spools), or another filament. Support for PLA/PETG and PVA release from PLA and PETG; Support for ABS releases from ASA and ABS.

The 3MF names every part with its filament, so each one lands on the right AMS slot.

## Switch bodies

Sizes and part numbers live in [kit/switches.js](../../kit/switches.js), shared with the switch panel model. Every number there says where it came from: Carling's STEP model, a listing, or an estimate.

| Body | Bare | With a stock cap |
|---|---|---|
| Unlit | V1D1S00B-00000-000 | V1D1S00B-AZC00-000 |
| Cool white LED | V1D1GWWB-00000-000 | V1D1GWWB-A7C00-000 |
| Blue LED | V1D1GXXB-00000-000 | V1D1GXXB-AUC00-000 |
| Green LED | V1D1GEEB-00000-000 | V1D1GEEB-AHC00-000 |
| Amber LED | V1D1GKKB-00000-000 | V1D1GKKB-ACC00-000 |
| Red LED | V1D1GCCB-00000-000 | V1D1GCCB-ANC00-000 |
| Bright red LED | V1D1GQQB-00000-000 | V1D1GQQB-ANC00-000 |

Lit bodies have two lamps. The top lamp is the backlight, on its own wire and dimmable. The bottom lamp is the indicator and lights when the switch is on. The capped numbers for lit bodies use a hard black Contura II cap with two bar lenses matched to the LED, decoded from Carling's ordering scheme. Confirm them with the seller before a bulk order.

## Backlit caps

The backlit window method cuts the label through the full face over each lamp and fills it with a second filament: black PETG face, translucent PETG windows. White LEDs with colored translucent PETG give a different color per switch from one part number. The lamp distance (9.5 mm from the pivot) is an estimate until measured on a real lit body.

## Printing

The 3D printing panel follows the project print setup rules. It ranks the three orientations and gives one line on why each wins or loses. Rank order: fits the printer, load along the layers, no supports on the show face, support volume, stands steady, height.

| Orientation | Pivot legs | Face | Supports |
|---|---|---|---|
| On its side | Bend along the layers | Clean, layer lines across it | Inside the cap: the upper skirt wall, the upper leg past the rim and the cam hang. About 160 to 200 mm². Tree supports inside only. |
| Face down | Bend across the layers | Flat face prints on the plate. A curved face hangs and needs support on the label. | None for a flat face. Support for PLA/PETG interface (PETG) or tree for a curved face. |
| Face up | Bend across the layers | Prints on top, iron it | The skirt rim hangs: built in breakaway comb, or slicer tree. |

A round hole entry makes the legs flex to snap on, so On its side ranks first, with supports inside. The slot entry barely flexes, so a flat face moves Face down to the top. That pairing, flat face, slot entry, face down, is the only one with no supports at all.

The page judges supports from the measured overhang with a 20 mm² allowance. The kit's 400 mm² allowance suits big parts and hid every overhang on this cap.

- **Support strategy**: Best for this orientation, none, painted for the slicer, drawn by this page, or slicer decides. A pick always wins; None warns how much hangs.
- **Painted for the slicer** (the default when the cap hangs). The 3MF paints triangles the way Bambu Studio's support painting tool does: enforcers under every overhang past the overhang angle, blockers on the face, the label and the pivot holes. A curved face printed face down gets enforcers on the face, for an interface in a support filament. The object carries its own settings in `Metadata/model_settings.config`: tree (manual) so supports grow on the paint only, tree style, top and bottom Z gaps, side gap, interface layers, build plate only, support and interface filament, wall loops, and ironing for face up. In the As printed view amber shows the enforcers and blue the blockers.
- **Filament numbers**: 1 is the face, then the label and the support filament when they differ from the face. Load them in that order in Bambu Studio, or remap after opening.
- **Drawn by this page**: kit/supports.js slices the part every 0.12 mm and drops ribs under each overhang, with the same gaps. Use it for STL or another slicer. It uses more filament than slicer trees.
- Shared settings: top gap (Auto: 0 with a support filament, 1 layer under ASA, 2 under PETG), side gap (0.35 mm), interface layers (2), overhang angle (50° from vertical), build plate only, and support filament on the interface only.
- **Teardrops** point up in the print for face down and face up. On its side the holes print round.
- Every support number is a starting point until the Print Test Bench gives tested ones.
- The model declares its loads, show face and flexing legs on `print`, for the kit's ranking.

### Checking a painted file

Open the 3MF in Bambu Studio and check, once per change to the file format:

1. The object list shows the cap with its label part, and the label on filament 2.
2. Support painting (the brush tool) shows the amber and blue areas from the page.
3. The object's settings show Support on, tree (manual), and the gaps from the page.
4. Slice: supports grow only on the painted areas, none on the face.

## Exports

3MF on one plate (each cap with its label and supports as one object, every part named with its filament), STL (zip with one file per part), PNG, settings JSON and a link that carries the settings.

## Files

    index.html    page shell; loads the shared kit from ../../kit/
    model.js      settings, presets, label tracing and build(), the geometry engine of record (JS, manifold-3d)
    model.json    title, summary, visibility, version and changelog
    thumb.png     catalog card art

Needs a network connection: three.js loads from a CDN, as on every kit page.

## License

© Ryan Mitchell — CC BY 4.0. See [LICENSE.txt](../../LICENSE.txt).