Double Edge Shaver (Yet Another)

by hemocyanin, published

Double Edge Shaver (Yet Another) by hemocyanin Aug 6, 2015
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Here is yet another double edge shaver (see below for other examples). This one is completely made of plastic with the only metal part being the razor blade itself (this is not necessarily an advantage because the head of the shaver is not heavier than the handle -- I think of it as a disposable travel shaver).

Random videos on how to use a double edge shaver: Men; Women

---- Assembly ----
The photos demonstrate how it goes together. Because the bolt is plastic, don't torque it down too much or it will break off in the handle.

---- Printing Notes ----
Printing the handle, the base, and the bolt are all very straightforward and they print well in in ABS or PLA. The clamp however is next to impossible to print well in ABS. At least for me. I'd love some suggestions because I really prefer the look and feel of ABS.

The best solution I could find for printing the clamp, is to print it in PLA in a vertical orientation with a 100% fill rate. The issue I had with ABS was getting the outward edges perfectly flat. These edges need to be flat otherwise the razor blade tends to be depressed into a broad "U" profile, which means a close (maybe too close) shave in the center of the shaver, and a not-so-close shave at the ends.

---- Usage Notes ----
There are three razor base designs with differing comb lengths. The longer the comb, the less likely you'll get nicks, but the less close the shave. If you've never used a double edge shaver before, start with the long comb -- it is the safest.

---- Issues with the ####### Clamp ----
I thought this was going to be a fun quickie project, but I was so wrong. I had started with the bolt and the clamp as an integrated single piece. I had terrible trouble with automated support because it would encapsulate the bolt and while breaking off the support, it was about a 50/50 chance I'd break off the bolt too. I tried printing it sideways with support only for the bolt, but the part was incredibly weak and broke very easily. I tried printing it top side down, but that caused ugly and uneven edges. I tried printing with the edges directly on the build plate, but mine requires heat (PEI surfaced) and that caused warping.

I tried a horizontal orientation with custom supports. These snap off nicely without damaging the bolt, but the larger issue is that I still can not get a super flat outside edge. I even tried varying the amount of support along the length of the piece so that curl and sag would counterbalance -- no dice. I tried adding horizontal support to keep the edge from bowing out when it is but a single strand -- no luck.

I include those parts here as experimental -- for others to experiment with if they wish. I've put way more time into them than I want, and I've basically decided that a horizontally oriented integrated bolt clamp, has got me beat.

---- Final Notes ----
I always include my source files (in this case in freeCAD file format) so if you want to make it better or scavenge bits and pieces, you don't have to deal with the hassle of pure STL files.

The examples here were printed on a LulzBot Mini in ABS and PLA.

---- Other Shavers ---
Jan 20, 2013: http://www.thingiverse.com/thing:43568 (includes source)
Mar 12, 2013: http://www.thingiverse.com/thing:61169
Apr 09, 2015: http://www.thingiverse.com/thing:763815

And then there's this. You don't even need a printer, just some PVC pipe. It's pretty awesome in its purely utilitarian aesthetic: http://brettbeauregard.com/blog/2010/03/diy-safety-razor-handle/

If I've missed any, let me know, I'll add them.

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Came out perfectly and really useful item. Thanks a lot!

Thanks for sharing!

Works well with an M5 screw instead of the plastic bolt. I heated the hexagonal screw head using a soldering iron so it melts into the clamp part. Then I cut the tread into the handle. Without a thread tapper, one could just drill into the thread hole in the middle and widen it just a little bit, then melt a nut into the shaft to accept the M5 screw. Might be even more durable than cutting threads into the plastic. See: http://www.instructables.com/id/Making-Custom-Threaded-Inserts-3D-Printing/?ALLSTEPS

That's a cool idea for fusing the bolt to the upper part of the shaver. I think I'm going to have to employ that strategy in other things.