Customizable 19" Rack Rails for Audio/IT Gear

About

I love 19 inch rack gear and I try and rackmount everything I can in my audio and home tech setup. Cutting aluminum beams isn't always an option so I thought I would make a custom setup for my electronics workbench to tidy up the power strips and give me a place to mount a small eurorack setup to interface with my inventions in progress. One thing I always wanted from my rack rails was indicators for the rack unit heights so I added the double diamond motif you can see in the pictures to help you visualize where things will go.

Hardware Required

The rails fit the standard M6 square nuts (I used Adam Hall 5660) do not use Hex nuts as they will be too thick. The couplers use M4 socket cap bolts (with a 7mm diameter head) to connect together and the feet also have 4mm holes so you could use m4 bolts or screws to mount it. 

Customizing

Each rail is fully customizable in OpenSCAD and I provided STL files for the 6U configuration Per rail you can decide the side(left/right) the number of rack units (U) and the feature on each end such as the feet, couplers or you can leave it blank.

Recommended Print Settings

For printing I used a 0.8mm nozzle with a .55mm layer height. with the standard settings except for a 10% infill They print really fast and strong in this configuration and have that nice striped textured surface that looks flawless. 

You could easily print them with a 0.4 nozzle but it would just take longer.

Supports

It was designed to print without supports.

The only overhangs are in the couplers but they are extra deep to allow for any drooping and printed fine without supports

Post Processing

I recommend going over the coupler faces with a hobby knife to make them smooth, or you could try ironing. This is just to make the coupler faces fit snug and not have any noticeable gaps. I cleaned up the bolt holes with a drill just to smooth them out for easy fit but it isn't necessary