3D model description
I was inspired by another designer who created a wallet/cup holder for the storage bin area behind the cup holders on 5th generation Rams with the center console. My issue was that I love to use bigger insulated water bottles and they don't fit in the existing cup holders nor the one the other designer created, and if they are put into the bottom storage area they flop around. So, I set out to make a functional holder that would work to solve this. In order to use this cup holder, you must position the sliding center cupholder area all the way to the front position and the new holders will be visible for use just in front of the arm rest; however, if the insert is not being used, you can push it back to the other 2 positions without any interference from the insert. Additionally, it will install on top of the existing liner that has the coin slots, but it must be pulled out and turned around so the coin area is positioned toward the back. This gives you the most amount of room under the insert. You can also remove the storage bin liner and it will still work.
I also understand that not all bottles are the same diameter. The openings on this cup holder are 4 inches in diameter, but I have also made inserts to reduce the size to some common bottle sizes. These should be made from TPU or similar flexible material to fit into the cup holder. These inserts have 0.1 inches added to the diameter size listed to allow for the bottles to slide in easily. The 3.75 insert works for my older 36oz Yeti Rambler bottle, and my 40oz Hydro Flask bottle. There is some room around the Hydro Flask in the 3.75 insert, but the Hydro Flask is just a bit too snug to easily pull out of the 3.5 insert.
Additionally, with such a large printed piece and being subjected to high temperatures inside your truck, I recommend printing the support piece as well to help keep it from sagging due to heat. Also, printing it in a material such as PETG, ABS, or other materials with a higher glass transition temperature will help keep it from shrinking and warping due to the heat. Be mindful that if the outside temperature is 90 degrees Fahrenheit or more, it will be well over 100 degrees inside an enclosed vehicle and this will cause some plastics to reach their glass transition temperature! Because of this, I do NOT recommend PLA, PLA+, or PLA Pro because of their low transition temperatures.
3D printing settings
I have tried it multiple ways to print this project, but 3-4 walls at 0.4mm each have been good to use. As for infill, I recommend 10% infill with a grid or similar pattern for structural integrity. These settings will use just less than 300g of filament, so make sure you have enough on the spool!
Also, I have printed this top down (with no supports) with great results, but it could be printed in a bottom down orientation as well. Supports are a personal decision, but I tried to design in such a way that they are optional but useful for best results if you have good settings.
You will need a printer with the ability to print at minimum 240mm wide or depth because of the size of the project. I used a CR-10 S5 with some slower settings and it took over 40 hours to print. YMMV
When printing the TPU inserts, orient them so the large, flat lip are down on the printer bed. No supports needed! They are flexible, so easy to slide in and insert into the cup holder.