Brackets and mounts
Resistor Lead Bending Tool Assembly
- Bounding box
- 1007.8 × 50.0 × 35.0 mm
- Engine
- Precision B-rep
- Parameters
- 42
- Published
- August 7, 2026
Download
Free to download and use. See the terms.
The prompt
Design a compact manual tool for bending only one lead of axial resistors intended for vertical PCB mounting. The resistor body dimensions are 4.7 mm diameter × 11.5 mm length (standard axial resistor). The resistors are supplied in a 20-piece DIP taped strip (ammo pack). The tool should allow the resistor to remain in the tape while one lead is bent, or allow very quick loading and unloading from the tape. Requirements: Bend only one lead while leaving the opposite lead perfectly straight. Produce a consistent 90° bend at a fixed distance from the resistor body. Avoid damaging the resistor body, coating, or lead. Minimize the force required to bend the lead. Allow fast repetitive operation for preparing many resistors. Be suitable for manual bench-top use. The operator should ideally complete one bend with a single lever or pressing motion. The resistor should be automatically positioned to ensure identical bend location every time. The tool should accommodate the dimensions of the resistor body (Ø4.7 × 11.5 mm). The design should prevent twisting or rotating of the resistor during bending. The bending radius should not create excessive stress on the lead. Preferred design ideas: Simple mechanical construction. Suitable for 3D printing with standard hardware (screws, pins, springs) if possible. Easy to assemble and maintain. Replaceable insert or adjustable stop for different resistor body sizes in the future. Deliverables: Complete CAD model. Exploded assembly view. Cross-sectional view showing the bending mechanism. Dimensions and tolerances. Explanation of the operating sequence. Recommendations for printable materials and any required metal hardware. The primary objective is speed, repeatability, and reliable single-lead forming for vertical resistor installation, not automatic feeding.
Parameters
| Name | Value | Range |
|---|---|---|
| Layout gap | 120 mm | 80 – 200 |
| Base length | 90 mm | 60 – 150 |
| Base width | 50 mm | 30 – 80 |
| Base height | 25 mm | 15 – 40 |
| Pivot boss diameter | 8 mm | 6 – 15 |
| Pivot boss height | 5 mm | 2 – 10 |
| Pivot hole diameter | 4.2 mm | 3.5 – 6 |
| Recess length | 24 mm | 18 – 30 |
| Recess width | 16 mm | 12 – 24 |
| Recess depth | 5 mm | 2 – 10 |
| Anvil hole diameter | 4.2 mm | 3.5 – 5 |
| Insert length | 24 mm | 18 – 30 |
| Insert width | 16 mm | 12 – 24 |
| Insert height | 10 mm | 6 – 15 |
| Cavity diameter | 4.7 mm | 4 – 6 |
| Lead slot width | 1.5 mm | 1 – 3 |
| Lead slot depth | 5 mm | 2 – 10 |
| Anvil diameter | 4 mm | 2 – 6 |
| Anvil length | 12 mm | 8 – 20 |
| Lever length | 80 mm | 60 – 120 |
| Lever width | 18 mm | 10 – 30 |
| Lever thickness | 10 mm | 6 – 15 |
| Pin hole diameter | 3.2 mm | 2.5 – 5 |
| Pin offset from pivot | 20 mm | 10 – 40 |
| Pin hole depth | 6 mm | 4 – 10 |
| Pin diameter | 3 mm | 2 – 5 |
| Pin length | 12 mm | 8 – 20 |
| Pad length | 15 mm | 10 – 20 |
| Pad width | 12 mm | 8 – 18 |
| Pad thickness | 6 mm | 3 – 10 |
| Spring wire diameter | 0.8 mm | 0.4 – 1.5 |
| Spring outer diameter | 5 mm | 3 – 8 |
| Spring free length | 15 mm | 8 – 25 |
| Spring turns | 8 mm | 3 – 15 |
| Pivot pin diameter | 4 mm | 3 – 6 |
| Pivot pin length | 20 mm | 15 – 30 |
| Return spring wire diameter | 1 mm | 0.6 – 1.5 |
| Return coil inner diameter | 4.5 mm | 3.5 – 6 |
| Return coil length | 10 mm | 5 – 15 |
| Return coil turns | 5 mm | 3 – 10 |
| Return leg 1 length | 15 mm | 10 – 25 |
| Return leg 2 length | 15 mm | 10 – 25 |
Every value above is a live dimension. Open a model like this in the editor and each one becomes a slider you can drag before exporting.
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