Bycicle AirTag Holder

This is a walkthrough of how I made an airtag holder for my bycicle and how you can make one yourself. :)

1. 3D Printer (In my case an Ender 3 1S)
2. PETG filament
3. A caliper
4. A CAD 3D software (I used OnShape)

This step is dedicated to collecting the necessary measurements and sketching the part that needs to be designed. A caliper will be needed—preferably an electronic one, as it's easier to operate and read accurate data from.

Since the AirTag will be mounted to the underside of the handlebar pipe, this is the area that needs to be measured. In my case, the diameter of the hole was 43 mm, and the diameter of the knockoff AirTag I used was 36 mm, which meant it would fit comfortably. The height of my AirTag was measured to be 7.66 mm, and the space between the pipe and the frame was roughly 1 mm.

*Measure the diameter of the pipe with the outer shell.

Now it's time to sketch the part in the CAD software of your choice. Make sure the dimensions match the data collected earlier.

Now, to make the sketch three-dimensional, it needs to be extruded. The base plate in the middle of the sketch can be extruded to 1 mm, the outer walls to about 14 mm, and the inner walls holding the AirTag in place to just above the AirTag's height—which in my case was 8 mm. Make sure to print a test model and adjust the dimensions based on your own bicycle.

Once the part is extruded, fillets can be added to enhance the model’s visual appeal. Two grabbing points can also be added in case the part needs to be removed. The grabbing holes can be modeled by sketching on the right plane and using the "Remove" option during extrusion, adjusting the extrusion with the "Starting Offset" option.

For this step, use PETG filament or any other with similar properties. I wouldn’t recommend using PLA, as it can be too brittle and may not withstand vibrations. Do not use any supports, and print the part with the flat side facing down.

When the part is printed, test if it fits the AirTag and sits snugly around the pipe. It should come off without requiring excessive force. If it's impossible to remove it by hand, you can use a pair of pliers.