STL Files
Intro
A slim, thermoformable AirTag holder designed to fit inside a hard-shell Ray-Ban glasses or sunglasses case. Keeps your AirTag secured and out of the way, your case rattle-free, and your glasses scratch-free.
Details
I kept forgetting my glasses case everywhere: in the car, at work, at home. An AirTag solved the "where are my glasses?!" problem, but created a new one. The AirTag would rattle around inside the case, slide out from under the lens wipe, and bounce against the lenses. It scratched them more than once.
So I designed this holder to keep the AirTag locked in place inside the case. The hard-shell case has a slightly concave bottom, which turned out to be the perfect spot: just enough unused space to tuck an AirTag away without taking up room you actually need. And there is still space to keep the lens wipe inside the case! The holder is printed flat, then thermoformed with a hairdryer to conform to that curved surface for a tight, flush fit. No supports, no non-planar printing, just heat and press.
If you keep losing your glasses case too, or your AirTag is already rattling around inside one, this holder was made for you.
Prototyping
I started by tracing the inside shape of the case onto sticky notes, then photographed the tracing with a ruler for scale and imported it into Fusion as a reference image. I scaled the image to the ruler and traced the outline to create a first crude prototype.
For the second round, I overlaid a grid on the tracing, which helped compensate for lens distortion in the photo and gave me more accurate reference points to plot the curves. After a few more prototypes and polishing in Fusion, the final model was ready.
The AirTag slot uses a compliant mechanism: 4 strategic cuts in the holder allow it to flex just enough to snap the AirTag in, then hold it securely in place. The holder stays rigid everywhere else.
Materials
I used Polymaker PolySonic PLA Pro White for this print, and printed on Bambu Lab A1 Mini.
Assembly Instructions
I recorded the assembly videos, edited them in Adobe After Effects, and used GIF Brewery 3 to convert them into GIFs.
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