So I have been looking at this thread since it started. I have been thinking of a way to 3D Print the hangers with one lead as a tube that contains the power wire. As to the catenary wire that could be done with varying length verticals that have a C-shaped piece at each end to hold and separate the longitudinal wires. The end insulators would be no problem. My resolution is 0.1 to .05 mm.
The issue is the upper stress from the pantographs against the continuous lower wire. To minimize that stress instead of the fixed wire as in this threads system, the resin hangers would be much more flexible as the pantographs move along the system. This is a similar flexibility as is found in the HO Marklin system.
Stay tuned.
