[Alex, Sander, Daniel]
 

The Thorlabs parts to make a cart with a breadboard top did not fit together. In addition, the POC001 cart could shake pretty easily with the included wheels. I therefore designed some custom plates, one set to attach new wheels from McMaster and another set to interface from the PWA075 to the B2436G Breadboard. To attached the plate to the cart for the wheels, I used Stainless Steel 15 mm long, button head M6 screws. To attached the McMaster Wheels to the plate, I used 3/4" long, 5/16-24 screws with 5/8" OD washers.

To attach the plate to the breadboard, I used a 3/4" long 1/4-20 button head screw with a lock washer (similar to this product) to prevent the plate from rotating (parts held by a single screw without a lock washer tend to rotate). To hold the PWA075 to the breadboard, I used some Thorlabs stainless steel 5/8" long, 1/4-20 screws with some washers.

To attach the PWA075 to the cart, I used a 55 mm long M12 set screw that I screwed into the PWA075 since that was a blind hole. We used 8 rotations to put the set screw into the cart. I used nuts and washers to prevent PWA075 and the cart from spinning on the set screw.

When possible, I used alloy steel fasteners for its strength. The parts from McMaster were fairly greasy, so I washed them in simple green in DI water (1:30 ratio), sonicated for 10 minutes, and washed in DI water.

I made the plates out of Aluminum 6061. Attached are the part files, STEP files, ProtoMax Waterjet machining files, and drawings for making the parts in the mill. I had to machine 2 plates that interface with the breadboard as drawn and 2 parts with the opposite face milled because the parts need the be flipped accross the axes transverse to the breadboard face. The plates were greasy, so I washed them in simple green in DI water (1:30 ratio), sonicated for 3 minutes, and washed in DI water.

We assembled everything together, and everything fits. See attached photo.