3D Printing & Tinkering
Billow Case Design:
Image 1: Front View
Image 2: Rear View
Image 3: Assembly View
Image 4: Before Solution
Problem:
Billow floats in a camping bag along with bug spray, sunscreen, citronella candles, and more. Not only can these chemicals and dirt contact the mouthpiece, but the billow is at risk of impact damage.
Solution:
Designed and printed (Filament Type: Bambu Lab’s PLA) a high-visibility holding case that rotates about mold-in-place hinges and securely snaps closed using an arched snap. The ribs on the interior of the case firmly hold the billow in place and ensure that rattle is not possible. For the final print, I would change the filament type from PLA to ABS or ASA for their superior impact and heat resistance.
Image 5: After Solution
Image 6: Print Expo
Bike Mount for Garage Transponder:
Problem:
Accessing a garage and apartment requires removing a transponder from a bag each time, a repetitive hassle, especially when riding a bike. Leaving it loose also exposes it to impact damage and increases the chances of it getting lost.
Solution:
Measured the transponder and bike stem, then modeled a custom mount in SolidWorks and printed it in PLA. The mount bolts directly to the bike, positioning the transponder near the handlebars for quick, one-handed access without needing to dig through a bag. Additionally, the designed tight interface ensures the transponder does not produce rattle.
Bike Control Module:
Problem:
Cyclists need quick, eyes-free access to navigation, music controls, and turn signals while riding. Fumbling with a phone mid-ride is dangerous and impractical. Existing bike accessories typically solve only one of these needs, requiring multiple devices and complicated setups.
Solution:
A custom ESP32-based handlebar controller that consolidates navigation shortcuts, media playback, and turn signals into a single, weatherproof unit. The system uses two wirelessly linked microcontrollers: a primary unit at the handlebars with four programmable buttons and indicator LEDs, and a secondary unit at the rear with six sequential turn signal LEDs. The handlebar controller connects to an iPhone via Bluetooth HID, triggering iOS Shortcuts for one-tap routing to saved locations and native media controls for hands-free audio. Turn signals activate a synchronized sequential lighting pattern across both units, providing visibility to drivers from behind while confirming activation to the rider up front. The entire system runs on rechargeable 18650 batteries and communicates internally via ESP-NOW for instant, reliable response.
Figure: PCB Schematic
Figure: PCB Layout
Figure: PCB Rendering
Fixing the Fridge…
The Problem:
The plastic plunger on a refrigerator door light switch broke after impact, disabling the interior light. The plunger is sold only as part of a complete switch assembly, making a direct replacement unnecessarily costly for an otherwise functional switch.
The Solution:
Measured the existing switch housing and door jamb geometry, then reverse-engineered the plunger profile in SolidWorks. The replacement part replicates the original fan-shaped rotating actuator, torsional spring interface, switch column engagement feature, and latch geometry. Printed in PLA, the part snaps directly onto the existing switch housing with no modifications to the surrounding assembly. V1 exhibited creep failure at the retention snap, so snap dimensions were adjusted in V2 to increase stiffness and resist deformation under sustained load.
Figure: OEM Plunger
Figure: Aftermarket (Cooler) Plunger
