How to fix your cable like a pro

Hands holding phone charger repaired with Sugru

This project brings industrial-quality production to your kitchen table! In the industry, they call it desktop manufacturing.

We developed a compression mould for the single most popular cable in the universe: the Apple Lightning to USB Cable. So you too can experiment with this exciting technology.

Whether it’s just for kicks or to start a bustling cable repair business, professional moulding is easier than you think.

All you need to create industrial-quality strain relief for your cable is a 3D printed mould, a single-use pack of Sugru Mouldable Glue, a paintbrush and some dish soap (washing up liquid).

Download the 3D file for free from MakerBot's Thingiverse, the world's largest 3D printing community, print it at home or find your local 3D printer at 3D Hubs

Mould pieces coated with soapy water

Step 1

Add a light coat of soapy water (that’s just a drop of dish soap in water) onto your mould using a paintbrush. Shake off the excess.

Sugru wrapped around charger

Step 2

Use half a single-use pack of Sugru and roll it into a long sausage, roughly the length of the mould. Press the Sugru flat and then wrap the Sugru around the cable and press it into a rough shape making sure that there is more near the connector end of the cable.

Charger with Sugru placed in mould

Step 3

Place the cable between the two mould pieces.

mould pieces pressed to shape sugru

Step 4

Press the two parts of the mould together and rock from side to side. This gives the Sugru into the mould shape and pushes the excess Sugru out. In professional compression moulding this is called flash.

excess sugru trimmed off the charger in the mould

Step 5

Lift one side of the mould off and trim off the excess Sugru.

mould pieces coated with soapy water

Step 6

Apply more soapy water to the mould and repeat the moulding and trimming process.

hands holding phone charger repaired with sugru

Step 7

Leave the Sugru to set and after 12-24 hours it will turn into strong and flexible rubber!