Rad bike battery TPU charge port cover

Made to fit a Rad Bicycle barrel plug charging port in a non-integrated battery. My battery plug didn't fall off, but the plug part ripped off of the flappy cover, threatening to get permanently wedged into the port and preventing charging.

I modeled it as close as I could to the original cap/seal on my own bike, the non-integrated 10.5Ah 504Wh radmission 48v battery.

I had no luck finding an OEM replacement part, Rad no longer makes the Radmission. There were a handful of etsy shops clearly selling 3d prints of dubious quality, so I made my own for $.02 worth of TPU and 15 minutes in Fusion360.

Print in TPU!!!

print SLOW! 15-20mm/s. I used a .4 nozzle, first layer .28mm, .16mm layers after. 6 bottom layers, 8 top layers. Layer 1 is printed at 230c, the rest at 225c.

2 walls, no infill. NO FAN!

The secret to printing small parts in TPU with any amount of fine detail is to print several together, assuming you’ve tamed the stringing issues already.