Replacement Handle for Zak Beacon Kids Water Bottle

My kid dropped their favorite Bluey water bottle, and the handle broke. We tried gluing, but it didn't hold. “Print a new one!” they cried. So, here I am after a bunch of measuring and modeling.

It turns out it's a Zak-brand “Beacon” water bottle, so this handle should work for other designs of the same model. Ours pictured is the 16-oz plastic version.

It's not quite as curvy as the original, but I was focused on making it dimensionally-accurate in the right places, first!

To assemble, align the handle horizontally to snap the disks up into their slots (just like the original removable handle).

Print Settings

I used PLA, as it's easy to print and somewhat flexible which is nice to get it to snap in well. However, it is not dishwasher safe, so be sure to pop the handle off before washing. Only wash with slightly warm water (to not soften the PLA) and a mild soap.

I suggest the following print settings (or their equivalents in your slicer):

• Orient on its side (should be the default from the model)
• 0.28mm layer height
• 3 walls for strength
• Sharpest corner Z-seam alignment with smart hiding
• 20% gyroid infill
• Tree supports for 40-degree overhangs (barely prints anything but it helps with the disks)

This seemed to be a good balance of print speed and strength, and it has held up well for a few months!