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Uploading this for anyone that may have the same issue and not want to pay $700 to get lexus to fix it.
Basicaly, when the center console lid gets slid back, It hits this plastic which applies all the force into two tiny 5 X 7 mm 3mm thick stretches of plastic in tension.
This is an incredibly dumb design and could easily be forseen with any amount of strucural analysis thought or test simulation.
Print with 100% infil at as fine a layer height you can manage, I used .25. (make sure that the infil is smoot and not rough as the layers will be in tension so they need to be perfectly solid)
When printed, pre-drill clearence holes in the top mounts to allow for the 1/4" screws.
Line up the printed piece with the base and pre-drill clearence holes through the piece and base and counter-bore with a larger drill through the plastic piece to allow for the flat head to rest on.
you can also use a strong bondant or JB weld to coat the piece before mounting on the base to have more strength in shear.
Lexus IS center console plastic fix by KFred25 is licensed under the Creative Commons - Attribution license.
So what's this mean?
We're sure KFred25 would love to see what you've printed - take a photo and share it on Thingiverse as a Make.
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