DIY Multipurpose 3D Print Removal and Cleanup Tool

This is a handy tool for any 3D printing enthusiasts. You will be surprised at how well it works and how often you will use it to remove prints from the bed of you 3D printer and then remove supports and clean up the 3D print. It's a pry bar on one end and a knife blade on the other. I made this using an Allen wrench because of the high carbon steel. (you can use any piece of 1/8th inch steel as you wish)

1/4" or 3/8" x 5" or 6" Allen Wrench

Grinder (a bench grinder will work but you can also use a belt sander or a file (depending on how patient you are))

Orbital Sander

Cup of water to cool it off if it gets too hot

Gloves (good leather gloves will help protect your hands from heat)

Pliers or Vice Grip

Rotary tool with grinding wheel attachment

Metal File

Wood for the handle

Glue

n95 Mask

Safety Glasses

Patience (the more you have the better this will work)

Clear an area of your shop where you can do grinding. there will be sparks and metal dust so make sure there is nothing flammable around.

Grip the Allen key with a vice or vice grips.

Using an angle grinder or hack saw remove the L shaped part half way at the bend (see photo)

Using an angle grinder with a 40 grit flap sander attachment begin removing the metal on the inside of the Allen key, you want to leave about 1/16th of an inch less than half way. use back and forth motions always moving and never letting the grinder sit in one place.

frequently cool off the metal with water. you must not let it get too hot or it will ruin the strength of the carbon steel.

flip it over and repeat. try to avoid hitting the pry bar section.

The above steps are easier if you have a 2x72 Belt Sander, however not everyone will have that and so I am making this the rough and dirty way.

look at the sketches above and try to duplicate the drawings. the idea is to slowly remove the parts of the metal and shape it into the tool.

After the rough grinding sand it from 100 grit to 320 grit with and orbital sander

Finally after the blade shape profile is formed angle it by sanding away at about 10 degree so the blade goes from 1/8th inch at the back to a fine sharp edge at the front.

Put a 320 grit sanding disk on a table and manually sharpen the blade edge using the sandpaper.

Final Sanding should be done by hand with 320 grit sandpaper.

Cut two pieces of hardwood to 1/4" x 1/8" x" 2 1/2" strips

Using a rounded chisel carve about 1/16th from the center of each strip

Glue the wood sides onto the handle with super glue. clamp it and let it dry

Using the orbital sander and 320 grit sandpaper gently sand away the edges and shape the handle as you wish.

On the sides of the sandwich of wood and steel simply sand away the wood until you are flush with the metal

At this point you should have a usable tool.