Introduction

Design Goals and Paths

The objective is a redeployable, fault-protective series of wire clamp pairs (each pair being electrically conductive).

Insulator Frame: HDPE

Conductive Bridge: Aluminum 6061T6 (abundant aluminum, easy to machine) (note: watch out for galvanic corrosion!)

Fastening Screw: Stainless Steel 304, socket head cap screw

You'll want to cut the thick HDPE to size, ex. 1/2" x 1" x Length

Also cut the thin HDPE to size, ex. 0.06" x 1/2" x Length

Also cut the aluminum flat to drilling size, ex. 1/8" x 1/2" x 6" for mounting onto a vise

Now drill the thick HDPE piece with a 4.5mm diameter drill bit for the screw terminal holes and a 5.5mm diameter bit for the mounting holes

Also drill the aluminum pieces with the 5.5mm diameter bit

Cut the aluminum lengths to use size ex. 1/8" x 1/2" x 1" for each conductive pair

Tap the screw terminal holes with an M5x0.8 tap

Melt on the thin HDPE onto the thick HDPE to divide each screw terminal pair

Yoonseo Kang - ykang404@gmail.com