Bike stand flexible bike protector sleeve replacement

My multi-bike stand had rubber mounts that protected the bike frames had worn away.

This was probably due to the design featuring rubber fin structures that moved back and forth as the bike was placed and then got caught under the weight of the bikes, depressing and breaking the fins over time.

Although not completely useless when the fins were gone, the bikes would hop onto the metal frame of the stand when moving other bikes, damaging paint and leading to rust and dents.

I designed a replacement to fit over the 20mm x 40mm rectangular hollow section of the frame. My original design was relatively flat and didn't provide much give in the centre of the valley to soften the impact on the frame of the bike.

My revised design features a convex hump to act as both a cushion and accommodate multiple angles of bike frames such as those for children which don't have a straight top bar and in different sizes. 

It works really well, and I have printed out enough to replace all the old rubber pieces. The infill is fantastic as suspension in the sealed print.

It should be possible to scale the .STL in your slicer for other dimensions of RHS or timber through simple calculations.

Printer settings below:

Material: TPU @ .2mm layer height

Infill: must be sufficiently high: 20%+, I recommend Gyroid as it touches the walls multiple times near the overhangs for a much cleaner print

Supports: NIL if printed on its side with the opening facing up.

Notes: An unworn nozzle and slowing down the speed slightly for the overhangs will help get a clean print as I found out the hard way. 

Fusion 360 file included.

NOTE: I've been informed this may be for a Thule brand rack, let me know if you can confirm!

Ferz out.