Scalable Fitness Bench Leg Cap

Scalable Fitness Bench Leg Cap

A simple replacement leg cap for fitness benches, gym equipment and round tubular frames.

The original model is designed for a 38.5 mm round tube, but the geometry is fully scalable, making it possible to adapt the model to many other tube diameters directly in your slicer.

This makes the model useful as a general replacement part rather than only for one specific fitness bench.

The cap features a cylindrical design with a textured external section for additional grip during installation and removal.

Original size

The uploaded model is designed for:

38.5 mm round tubing

If your equipment uses the same diameter, you can print the model at its original 100% scale.

Scaling to other sizes

For a different tube diameter, simply scale the entire model proportionally in your slicer.

You can calculate the required scale using:

Target diameter / 38.5 x 100 = Scale percentage

For example:

• 30 mm tube = approximately 77.9%

• 32 mm tube = approximately 83.1%

• 35 mm tube = approximately 90.9%

• 40 mm tube = approximately 103.9%

• 45 mm tube = approximately 116.9%

• 50 mm tube = approximately 129.9%

Use uniform scaling so that all dimensions remain proportional.

Because printer calibration, material shrinkage and actual tube dimensions can vary, measuring the tube with a caliper before printing is recommended. A small adjustment to the calculated scale may be necessary for a perfect fit.

Recommended materials

TPU is a good choice when flexibility, grip and impact resistance are important.

PETG works well for a stronger and more rigid replacement.

PLA is suitable for testing dimensions and can also work for lighter applications.

Printing

The model is straightforward to print and does not require complicated assembly.

For a new tube size, printing one cap first is recommended. Check the fit and make a small scaling adjustment if necessary before printing the remaining caps.

Possible uses

The scalable design can be used for fitness benches, weight benches, home gym equipment, exercise machines, furniture, workshop equipment and other applications using round tubular legs or frames.

The 38.5 mm version is the original size, while other sizes can be created directly through uniform scaling in your slicer.

For Users in Serbia

If you are located in Serbia and need this replacement part but don't have access to a 3D printer, feel free to contact me directly on Facebook.

I can print the part for you using PETG.

Facebook: https://www.facebook.com/ivijan.stefan/

Please note that this is an unofficial 3D-printed replacement for a safety-related component, not a certified original part.