I wanted a truly lightweight, adjustable way to wear the Google Fitbit Air during workouts without being restricted to just the wrist. To achieve a perfectly contoured fit without the messy surface finish that comes from printing on supports, I designed this frame to be printed completely flat and heat-formed using hot water.
By leveraging the thermoforming properties of 3D-printed plastic, you get a pristine surface finish, maximum structural integrity, and an exact fit against the device's geometry. The frame is designed with continuous concentric paths to ensure the arms never snap under tension..
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Features
Flat-Print / Heat-Formed Design: Prints completely flat without supports for a flawless surface finish, then easily shapes to the device using hot water.
Continuous Ring Strength: Engineered to print as continuous concentric lines, maximizing structural integrity and arm flexibility.
Skeleton Frame: A high-strength, ultra-lightweight design that strips away bulk while maintaining a secure hold.
Universal Versatility: Can be comfortably worn on the wrist, forearm, bicep, calf, or ankle depending on your activity.
Optional Tri-Glide Slide: Includes a printable tri-glide buckle if you want to make a strap from scratch.
LED Status Pass-Through: Features a precision cutout so you can check your battery status at a glance without removing the tracker.
Official Specification Matching: Designed using official dimensions provided by Google for a secure, exact-fit.
Strap Compatibility Guide
Off-the-Shelf Options:
Recommended: COROS Heart Rate Sensor Replacement Band (My go to for all day comfort) (24mm)
Note: The printed part will look slightly longer than the tracker when printed; this extra length is required to accommodate the curve during heat forming.
Heat Forming Instructions
Heat Water: Bring water to 65–75°C (149–167°F). Do not exceed this temperature, or the part may shrink.
Soften: Submerge the flat print using tongs or chopsticks for 10 seconds.
Dry Quickly: Drop the print onto a towel to remove excess hot water.
Shape: Quickly snap the print onto your Fitbit Air, bend the arms down to your desired angle, and hold for a few seconds until it cools and locks its shape.
DIY Band Guide
Loop the strap around the middle pole of the Tri-Glide Slider and sew closed
Feed the strap through one side of the FitBit Air holder
Feed the strap up and down through the Tri-Glide Slider
Wrap under everything and loop the end around the other side of the FitBit Air holder
Sew the end around the FitBit Air holder
Credits / Licensing
Design by PixelFanLabs – With a curious mind, integrity, and your hands in the soil, you can create anything.
License – All Rights Reserved
Personal Use Only: You may print this for your own use.
No Redistribution: Do not re-upload or distribute these digital files on any other platform.
No Derivatives: Modification of this design—including the removal of the engraved PixelFanLabs signature—is strictly prohibited.
PixelFanLabs
