Summary

I've had this nice, basic, magnetic tip Craftsman screwdriver for decades. When I purchased it, I also picked up a set of Torx bits to store in the handle.
The original plastic cap is lost to the ages. It was made of a softer plastic and was always the weakest part of the kit.
For many years, I've just used a cork to keep the bits in. Now that I have my shiny new CR-10s, a replacement cap seemed like a good project.

Print Settings

Printer:

CR-10s

                                            <p class="detail-setting rafts"><strong>Rafts: </strong>                     <div><p>No</p></div></p>                                                                                <p class="detail-setting supports"><strong>Supports: </strong>                     <div><p>Yes</p></div></p>                                                                                <p class="detail-setting resolution"><strong>Resolution: </strong>                     <div><p>.1</p></div></p>                                                                                <p class="detail-setting infill"><strong>Infill: </strong>                     <div><p>20%</p></div></p>                                                        <br>                        <p class="detail-setting notes"><strong>Notes: </strong>                    </p><div><p>To keep the smooth curve to the top, I printed thread side down with supports.</p></div>

Post-Printing

Just remove the supports and thread it into the handle a few times to get things working smoothly.
I printed this at .1mm and I had to work it in by turning and then backing off a half dozen times. After that, it has remained snug but removable.
I did not sand or paint the plug. The print lines add a little extra gripping texture.

How I Designed This

I measured the handle and printed a number of test threads to dial in the exact thread settings. I created a flat-topped version that printed without supports and I used that version for a number of weeks. However it wasn't confortable or attractive.
This was modelled up in Fusion 360 and sliced in Simplify 3D. (Cura works fine as well, but the supports are a little harder to dig out.)

Craftsman Screwdriver Replacement Cap

Craftsman Screwdriver Replacement Cap

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