Compact multimaterial Telepass box & adjustable 26mm handlebar mount (fits 70 × 20 mm)

Small weather-resistant box designed to hold an Italian Telepass unit (internal cavity 70 × 20 mm) with a multimaterial lid seal and a 6‑piece mount system that clamps to a 26 mm handlebar. The design allows the box to be mounted in six different orientations by sliding the carriage along prismatic grooves. Intended for motorcycle use — robust main body with a TPU gasket and a soft TPU contact pad to protect paint and add grip.

What’s included

• Box base (multimaterial part: rigid base + TPU gasket)

• Box lid (rigid) with and w/ logo 

• Click latch (single-material)

• Sliding carriage and prism pin (single-material)

• Half‑ring clamps (single-material)

• TPU handlebar pad (single-material)
  Total parts: 7 printed pieces (1 multimaterial lid + 6 single‑material parts).

Dimensions

• Internal cavity: 70 mm × 20 mm (fits typical Italian Telepass).

• Handlebar clamp diameter: designed for 26 mm tube.

• Hinge pin holes accept 2 mm metal pins (one 60 mm long, one 20 mm long) OR 1.75 mm filament as a printed pin substitute.

Recommended materials

• Rigid structural parts (box body, carriage, clamp halves, latch, prism pin): ASA, PC, Nylon, or PLA‑HT (I recommend ASA / PC for outdoor/motorcycle use).

• Gasket and handlebar contact pad: TPU (shore 85A–95A recommended).

• Hinge pins: 2 mm metal pins (recommended). Plastic filament pin (1.75 mm) can be used in a pinch.

• Fasteners / hardware: 2 × M3 × 20 mm screws + 2 × M3 nuts.

Print notes & settings

• Multimaterial lid: print as two-material part (rigid base + TPU gasket). If your printer does not support multimaterial extrusion, you can try to print gasket and base separately and glue/insert the gasket.

• Layer height: 0.2 mm recommended for good surface/detail. For a smoother finish use 0.12–0.15 mm on the lid.

• Infill: 20–40% for structural parts; higher for clamps if you expect heavy loads.

• Perimeters: 3 perimeters recommended for structural strength on clamps and carriage.

• Supports: Box can be printed without supports; Half-ring can be printed on the side to improove mechanical strength for tightening. The arm with rails is best printed with supports.

• Orientation tip: print the arm/rail piece tilted 45° resting on one chamfered edge. This improves the screw seat quality and reduces risk of delamination when tightening.

• TPU printing: print TPU contact pad and gasket at low speed (15–25 mm/s). Use direct drive or proper retraction tuning to avoid oozing.

Assembly & hardware

• Hinges: use two 2 mm metal pins (recommended): one 60 mm and one 20 mm. You can substitute with 1.75 mm filament pins if needed, but metal is stronger.

• Secure hinge pins with a single small drop of superglue on at least one side to prevent axial movement.

• Mounting to handlebar: two clamp half‑rings wrap around a 26 mm tube and tighten with 2 × M3 × 20 screws. Insert M3 nuts into the lateral slots built into the clamp with carriage before final assembly.

• Sliding carriage: the base has six prismatic grooves — slide the carriage rails into the desired grooves to set one of six mounting positions. Lock the carriage with the printable prism pin included.

• Latch: snap‑click closure on the lid holds the box shut; the gasket provides water resistance.

Tolerance & fit

• The internal cavity is 70 × 20 mm. add a thin foam insert to prevent shaking.

• The clamp is sized for a 26 mm pipe. Ask me for different diameter if you need, I will add to he models.

Safety & usage notes

• Designed for small electronic unit only, there is no safety lock so dont store vauable things nor delicate thinghs.

• Periodically check screws and hinge pins for wear

• Use the TPU pad on the outer clamp surface to avoid damaging painted handlebars.

• When tightening screws, avoid overtightening to prevent plastic stripping — use threadlocker or replaceable steel nuts inside slots if you expect repeated removals.