This little project presents a fuse holder for placing a standard automotive 1A/2A/3A/5A/10A/15A fuse onto a PCB.
The contacts to the fuse spades are made by 3mm large solder tabs. These are bent around the fuse tabs in "M" shape, and the the ends are pushed through the diagonal channel that lead to the solder cavities underneath the fuse holer. Then, the automotive fuse is used to push the solder tabs into place. For best contact, just use the ends of the solder tabs that protrude on the bottom of the holder for soldering the fuse holder onto the PCB.
If this is not possible because of the holes on the PCB being to small, you'll need to cut the soldertabs and insert
two short pieces of 20ga (~0.8mm diameter) solid copper wire are inserted through the vertical wire holes and horizontal channels to overlap with the solder tabs in the solder cavities. Soldering has to be done quickly in order not to melt the ABS plastic.
The distance between the wires is 0.4in / 10mm, and the placement of the wires is done somewhat asymmetric, in order to fit the space on the PCB when replacing the 11A MFR1100 auto-resetting PTC fuse on my RAMPS 1.4 board.
Working with fuses and fuse holder always bears the risk of something going wrong - and that can quickly become dangerous!!! Thus, you should only build and use this fuse holder if you know what you are doing and assume the full responsibility for using it. I explicitly decline any responsibility!
I printed this object on my DIY box-frame Prusa i3 using a 0.4mm nozzle with an extrusion width of 0.56mm and a layer height of 0.25mm, on a plain mirror washed with concentrated lemon juice. Given that the part should be as heat resistant as possible (especially if lead wires are soldered to the solder tabs), ABS is definitely a must here.
You should feel some resistance when inserting the fuse blades into the folded solder tabs in the holder, as to be sure that there is a good contact. A bad contact leads will cause the holder to get hot (and eventually melt or even burn!) and may also cause malfunctioning of the device you are using it with, due to the excessive voltage drop over the bad contact.
When soldering the finished fuse holder to the PCB, make sure not to apply the heat for too long, as otherwise the solder joints (if any) inside the fuse holder might melt!