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Bike Handlebar Plug

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Hotend.JPG This page is part of a Principia course ENGR242: 3-D Printing Technology

Please leave comments using the discussion tab. The course runs in the Spring semester. It is not open edit.

Bike Handlebar Plug[edit]

Project developed by user: Kirill Kudaev
This OSAT has been designed but not yet tested - use at own risk.
This OSAT has been prototyped.

You can help Appropedia by contributing to the next step in this OSAT's status.


  1. A customizable Bike Handlebar Plug designed using OpenSCAD.

Bill of Materials[edit]

  • A bike with a handlebar
  • 3D printed Bike Handlebar Plug

Tools needed for fabrication of the OSAT[edit]

  • Jellybox or similar RepRap 3-D printer

Skills and Knowledge Necessary to Make the OSAT[edit]

  • None except for having an OpenSCAD software in order to customize the plug.

Technical Specifications and Assembly Instructions[edit]

  1. Both a .scad and a .stl file will be provided through a Github link for easy download. Files
  2. To successfully print the file make sure your printer is calibrated for a successful print, ie. the extruder produces enough filament for an accurate and reliable print.
  3. A print time is estimated to be roughly 50 minutes at a 20 percent infill rate. Times will change based upon individual printer settings.
  4. Assembly for the OSAT product takes seconds and involves taking the print and plugging it in the bike handlebar.

Common Problems and Solutions[edit]

  1. Make sure to customize the plug parameters using OpenSCAD software in case the default design doesn't fit the handlebar

Cost savings[edit]

  1. Normal price for Bike Handlebar Plug on the modern market ~$15
  2. A commercial equivalent can be found [here](https://www.amazon.com/Fyxation-Bar-End-Plugs-Black/dp/B006GHDE68/ref=sr_1_1?ie=UTF8&qid=1493165780&sr=8-1&keywords=bike+handlebar+plug):
  3. Average cost per commercial Bike Handlebar Plug $15, cost to produce a 3d printed Bike Handlebar Plug, < $1.00


Picture Title Description
BikeplugOpenSCAD.png Bike Handlebar Plug OpenSCAD model Designed using OpenSCAD. File
BikeplugmySTL.png Bike Handlebar Plug STL model Designed using OpenSCAD. File