About this project
A butt hinge with interleaved knuckles and a pin, sized to whatever you are hanging. Two leaves, an odd knuckle count so the pin is captured at both ends, and a clearance you tune to your printer.
Hinge
Overall open width, leaf height and leaf thickness. Knuckle count is a choice of odd numbers from 3 to 11 - more knuckles spread the load and look finer, fewer are stronger individually and print more reliably.
Clearance is the number that decides whether this works. It sets the running gap between knuckles and around the pin at once. Too tight and the hinge is seized out of the printer; too loose and it rattles. Start at 0.4 mm and adjust by 0.05.
Pin
By default the pin diameter follows the leaf thickness, which keeps the barrel proportioned as you change the leaf. Turn that off to enter a diameter directly.
The pin can print fused to the female leaf - print in place, snap the leaves together, done - or as a hole for a separate pin if you would rather use a length of filament or a steel rod.
Fasteners
Holes per leaf, in one or two columns, with separate thread and head diameters and a counterbore depth. Hole positions are derived from the leaf size and the margin, so they stay evenly spread whatever else you change.
Assembly
Show either leaf alone for printing, and swing the throw angle to check the hinge clears whatever it is mounted to before you commit.
While you dial it in
Readouts show the open size, the knuckle layout with its real clearance, the pin, and the hole pattern. The design check watches the two failure modes that actually bite: knuckles narrower than the gaps between them, and a counterbore that breaks through the back of the leaf.