The quickest way to remove prints from a PEI sheet is a quick, sharp blow from a hammer or mallet. I didn't want to use my actual metal hammer, so I decided to print one. Unfortunately, all of the models I found either required supports, needed glue, or had obvious weak points. So, I decided to create my own!

This light-duty mallet is designed to be reasonably strong, while remaining easy to print. First, the handle is printed with long layer lines, so it's resistant to snapping. Second, the prongs of the handle are fixed in place by the lock: this makes it nearly impossible to remove the head without damage. Third, the strength of the mallet is easy to increase by adding more shells. Finally, because this model consists of multiple pieces, you can customize the color scheme.

The mallet is meant for removing prints, assembling other prints, and maybe loosening a stuck part. It is not heavy duty or super strong! It is extremely important that you do not use this mallet on nails or other metal objects. It's plastic: it can deform, crack, shatter, or snap.

Don't forget to like this model! If you print one, please share a make!

Eye Protection Warning

Always, always, always use eye protection when using this (or any) hammer or mallet. Items can shatter, tools can chip, or debris can be launched. This can cause permanent eye damage or other bodily injury. The risk to your eyesight is not worth it: wear safety glasses.

Shatter Warning

This mallet is made of plastic: it can chip, shatter, or break. Use caution when hitting any solid item! Do NOT use this mallet to hammer nails or hit anything extremely hard!

Print Settings

• Nozzle Size: 0.4mm
• Layer Height: 0.2mm
• Vertical Shells: 4 for head and lock, 3 for grip
• Top/Bottom Layers: 8 for head and lock, 6 for grip
• Infill: >50% for head, 15% for lock and grip (see notes below)
• Supports: Absolutely not!

Print one head, one grip, and one lock. The parts are already oriented correctly in the STL files.

Be sure to calibrate your e-steps and flow rate before printing!

The tolerance between each piece is 0.2mm, so you may also need to reduce your flow rate (mine was set to 97.5% and everything fits perfectly). This tolerance makes each fit very tight, but it also makes the mallet extremely difficult to disassemble (you don't want it flying apart, do you?).

The settings above will create a plastic shell of 1.6mm around the head and 1.2mm around the grip. I would not suggest going thinner unless you're making a decorative print.

The infill percentage of the grip and lock doesn't really matter. Increasing the infill of head will make the mallet feel more substantial and hit harder, but doesn't have any significant impact on overall strength of the mallet.

I printed the head and grip with PLA+ and the lock is PLA. Do not use filament that is overly flexible or brittle (silk, wood, etc.)!

Assembly

Assembly is made easier by using a hammer or mallet, but it's not required. And I do appreciate the absurdity of using one mallet to assemble another mallet...

1. Insert the pronged end of the grip in to the hole in the head. The orientation of the head doesn't matter. The grip won't go in straight (perfectly perpendicular to the head), so simply "wiggle" it into place. Be sure it "snaps" when it's fully inserted.
2. Insert the lock into the top of the head between the prongs of the grip. This can be difficult to get started, so be patient and carefully apply more force. Once the prongs of the lock are no longer visible, you can safely apply more force to the lock until it's fully inserted.
3. Carefully hit things? I don't really know; these lists just look weird with only two entries.

Please note that this mallet is not designed to be disassembled once the lock is in.