Here are some of my ideas for fixing the problems identified in the previous iteration. Overall, the design hasn’t changed significantly, but suggested improvements should make a tangible difference.
Suggested improvements include…
1. Moving the panels (that the cap clips into) at the end of the base component to the sides, providing better and more natural grip.
2. Integrating the slots into the design of the thread hole location pegs – allowing a larger slot to be used (enabling easier assembly) and to provide a flatter edge on the perimeter of the component to make removal and sanding of excess material easier.
3. Changing the slot to a V-shape to remove the need for support material.
These improvements should make both manufacturing and use much easier, however, I would like to change/develop the design even further to improve it’s appearance and function more dramatically.