Ultralight Bike Bar End Plug (Parametric)

Originally inspired by Lucendi’s SUB1 bar end plug, I wanted to make something that took advantage of ellipses for retention. Essentially I made the part of the plug that goes into the bar an oval—wider than the ID in one direction, and narrower than the ID in the other direction. Once pressed into place it holds really well.

I’ve included open and closed versions of the plug, in common ID and OD sizes for mountain bikes, road bikes, and kids bikes. You can also download the STEP or F3D file and make whatever custom sizes you want. For example, the stock plugs extend to the OD of the bar only, but if you want to have them cover your lock-on grip or bar tape as well, you can customise that. Just measure the OD of your grip or bar tape, and enter that value in the BarOD parameter.

Should work with no supports in standard settings—it's so thin that it should print all walls, no infill. 

• ~2g for the pair depending on parameters and filament used.
• 7-10 min print time on Bambu X1-C at 0.12mm layer height.
• Adjustable parameters to match the ID and OD of your bar.
• Hole and no-hole versions in common sizes for MTB, road, and kids bikes.
• Recommend PA-CF, ASA, or other material that’ll handle direct sunlight and hot temperatures.

Note: I haven’t tested this design with road bars and bar tape yet. Feel free to be the guinea pig and let me know how it goes. It’ll cost you about 4 cents if it doesn’t work.