TLA3 — Korouei

Introduction

The TLA 3 is a fully 3D-printable, 3-stage telescopic actuator designed for makers, hobbyists, and robotics enthusiast.

It features a modular, tool-free assembly with no need for screws, glue, or external hardware. This guide provides clear, step-by-step instructions for printing and assembling the actuator using its 13 core components.

Components

The actuator is assembled from 13 individual components listed below:

Printing Requirements

Assembly Instructions

Step1) - Assemble BC1 and Leadscrew 2

Insert BC1 into the slot of Leadscrew 2 (Leadscrew 2 must be able to rotate freely around BC1).

Step2) - Insert Leadscrew 1

Insert Leadscrew 1 into BC1 and gently rotate until fully seated (before rotation occurs the rails of Leadscrew 2 will need to align with the guides of Leadscrew 1).

Step3) - Assemble BC2 and Leadscrew 3

Insert BC2 into the slot on Leadscrew 3 as in Step 1

Step4) - Assemble Leadscrew 3 into the main stack

Take the Leadscrew 3 + BC2 assemble from Step 3 and gently insert it into the Leadscrew 2 + BC1 + Leadscrew 1 assembly from Step 2.

Rotate Leadscrew 3 slowly until it threads fully into Leadscrew 1.

Step5) - Attach Cylinder 3

Make sure to rotate Cylinder 3 fully until its flush and securely seated.

Step6) - Insert Cylinder 2

Slide Cylinder 2 into Cylinder 3.

Gently pinch opposite sides of Cylinder 2 to slightly flex its walls, allowing the pins on BC2 to click into the holes in Cylinder 2.

Step 7) - Insert Cylinder 1

Repeat the same procedure:

Slide Cylinder 1 into Cylinder 2, again flexing Cylinder 1 slightly so that the pins from BC1 snap securely into the holes.

Step 8) - Slide into Cylinder 0

Insert the full cylinder assembly into Cylinder 0.

Important:

Align the runner (track guide) on the inner assembly with the continuous slot inside Cylinder 0. The shorter slots inside Cylinder 0 act as the mechanical stops, they are not for alignment.

Step 9) - Insert End Stop

Press-fit the End Stop into the bottom of Cylinder 0.

Start by pressing at one point and slowly work your way around to ensure a tight, even fit. The tight tolerance ensures the internal mechanism stays under compression without popping out.

Step 10) - Insert Rotary Dial

Push the Rotary Dial into the end of Leadscrew 1.

It may feel loose or appear shallow, this is intentional. The final screw will secure it into place and allow smooth dial operation.

Step 11) - Secure with End Screw

Use a small flathead screwdriver to screw in the End Screw (part 13) into the center of the Rotary Dial.

Step 12) - Press-Fit the Hat

Finish the assembly by press-fitting the Hat (top cap) into the top of Cylinder 3.

This completes the actuator build.

Note: During initial use, the extending motion of the actuator may feel slightly clunky or juddery. This is expected to some degree. The internal mechanisms will naturally smooth out over time through repeated operation as the components wear in and self-lubricate through minor surface abrasion.

Feedback & Reviews

This project began as a simple curiosity, I wanted to see if I could design and 3D print a compact telescopic actuator for my own robotics experiments. What started as a fun challenge quickly turned into a passion project, leading me down a rabbit hole of trial and error, dozens of prototypes, and countless hours of refining the design.

The result is TLA 3 – a delicate mechanical system that can be printed and assembled without the need for screws, glue, or tools, making it accessible to people of all ages and backgrounds. It’s a fully self-contained, modular design that you can bring to life with nothing more than a standard 3D printer.

Whether you’re a seasoned engineer, an aspiring maker, or a student just getting started, I hope this actuator finds its way into your creative projects, from home to robotics to automation experiments, and maybe even future applications like building robots in space.

If you have feedback, ideas for improvement, or want to share how you’ve used it, I’d love to hear from you.

You can reach out to me at korouei@gmail.com