I modeled these after the clipper guards that came with my Surker hair clippers. Mine only came with sizes up to #4, and I wanted more options!

This is an updated version from my previous. The “fins” are now much better supported and less likely to snap at the layer lines.

Printing

I recommend a 0.15 layer height, but .20 and .10 should work as well (YMMV). Other than that, you should be able to print as-is.

For ease of printing, I've included built-in supports. These improve bed adhesion and stabilize the fins to prevent wobble while printing. They are designed to break away cleanly so you shouldn't have to post-process.

The face plate is a 70° overhang, so you may get some sagging on the underside. If you don't have sufficient cooling for the overhang, just generate some supports for that face. If you're feeling confident and would like to try without the built-in supports, see the section below on customization. 

PLA or ABS is recommended. I have not yet tested this new design in PETG, but in the previous version it was too brittle. 

Customization

The CAD model is available on OnShape. You will need to sign up for a free account to export. You can easily switch the guard size using the configuration panel in the upper left. You can go as high as #20 if you want, but at that point you might be dealing with strange structural issues. I haven't tested above #12.

The built-in supports can also be disabled by unchecking the “supports” checkbox. 

Changes from V1

• Fillets have been added along the connection points of the “fins” to make them much more resilient to bending. 
• Built-in custom supports to help stabilize fins during printing, reducing wobbling
• Debossed text instead of embossed. It doesn't look as good, but the embossed text prevented the face plate from sitting flush with the clipper.
• Tapered fins