HT-Pipe-Lid_DM100

V1 : old design (see white picture)

• DM100
• two grooves
• Files for version 1 : .stl + .ipt + .3mf (-V1)

V2 : New design (see black picture)

• DM100 (99.6mm)
• customizable!
• with 2D drawing (dimensions in mm)
• one groove for O-ring (95 x 2.5 NBR 70) + link
• Files for version 2 : .f3d (fusion360) + .3mf (-V2)

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V2 :

Practical sealing cap for pipes with approx. 100 mm inner diameter.

Since commercially available HT pipe caps (mostly DN110) do not fit into standard 100mm pipes, I designed this cap myself from scratch. It is perfect for cleanly sealing unused pipe openings.

I successfully use this model for two purposes:

1. Extractor hood: For sealing 100mm exhaust pipes.
2. Chimney / Fireplace: For covering an old, no longer used stove pipe opening.

Note on my use: Since 100% hermetic laboratory sealing was not required at my installation sites, I use the cap in my home completely without an O-ring. Due to the precise fit and the layer lines of the 3D print, the cap already sits snugly and perfectly fulfills its purpose. However, if absolute gas or odor tightness is required, a rubber seal can be retrofitted (dimensions see below).

Construction Details & Exact Dimensions:

• Outer diameter: The cap has an outer diameter of 99.6 mm. This leaves a razor-thin gap of 0.2 mm around the 100mm pipe – perfect so that the cap slides in effortlessly despite minimal 3D printing tolerances and slightly oval sheet metal pipes.
• Optional O-ring groove: The groove bottom diameter is 95.4 mm (groove depth of 2.1 mm). The groove width is 3.5 mm, so that a rubber has enough space.
• Optimized lead-in chamfer: A flat 2x30° lead-in chamfer is integrated on the front. This allows the cap to self-center during insertion and slide in effortlessly.

Optional Accessories (for “100%” sealing):

If you want to insert the cap absolutely airtight and odor-proof, you can place a very affordable standard O-ring into the groove. The design is precisely optimized for this:

• O-ring dimensions: 95x 2.5 mm (95 mm inner diameter, 2.5 mm cord thickness)
• Material recommendation: NBR 70
• Installation tip: Moisten the O-ring with a little soapy water before insertion, then the cap will slide perfectly into the pipe.
  
  Matching O-ring on Amazon: 👉 https://amzn.to/3S6rXdi(95x2.5mm)
• (Note: The link above is an affiliate link. If you purchase the O-ring through this link, you support me with a small commission from Amazon. Of course, this will not incur any additional costs for you! Thank you for your support!)

Print Settings:

• Material: PETG or ASA/ABS recommended (especially for chimneys or in case of residual moisture). However, PLA works just as well indoors in dry conditions.
• Infill: 15% - 20% (Gyroid or Grid)
• Walls: At least 3 walls for sufficient stability.
• Support: Not necessary (the flat 30° chamfer can be printed cleanly without any support).

Note: This is a standalone, functional new design for DIY needs.