Crutch Handle TPU Cushion Pad

This is a soft, printable cushioning pad for the handle of crutches.

It is designed for users who find the original rigid handle too thin and uncomfortable. The pad increases the handle diameter from 30 mm to 40 mm, which makes it especially suitable for taller people with larger hands.

The pad slots onto the handle and already works well that way. If desired, it can also be glued in place for a more permanent attachment.

I recommend printing it in a soft TPU. In my case, I used ColorFabb VarioShore TPU at 60A with 45% infill. However, flexible materials can behave very differently, so you should evaluate the final feel and compression behavior with the material you have at hand.

The part contains very steep overhangs. For best results, it is recommended to use one or more of the following approaches:

• very low layer height

• adjustable layer height

• supports

• thorough cleanup of the inside after printing

A combination of these methods may give the best result.

The photos show a print of a previous version. The file provided here has been slightly adjusted to make printing easier.

Print settings / notes

Recommended material: soft TPU
Example material used: ColorFabb VarioShore TPU 60A
Example infill: 45%
Attachment: press fit onto handle, optional glue
Important: check fit and comfort with your own crutch model and filament