Vaseline Lip Therapy Keychain Cap / Protective Cap Holder

Vaseline Lip Therapy Keychain Cap

A compact 3D-printed keychain holder designed for the Vaseline Lip Therapy lip balm.

The model reuses the original Vaseline screw cap. The original cap is inserted and permanently bonded into the printed shell, retaining the original threads and sealing surface while adding a protective outer shell, extra grip and an integrated keychain loop.

I designed the model from measurements of an original cap and tested the final version in PETG.

Assembly

The original Vaseline cap needs to be bonded into the printed shell.

For my build, I lightly roughened both mating surfaces, cleaned them and used an adhesive suitable for PP/PE plastics. Insert the original cap completely and allow the adhesive to fully cure before use.

Always test the fit before applying adhesive.

Printing

PETG is recommended for the final part, especially for actual keychain use. PLA should also work well for test prints.

Recommended starting settings:

• Material: PETG

• Layer height: 0.12–0.20 mm

• Walls/perimeters: 3–4

• A smaller or adaptive layer height can improve the finish around the rounded keychain loop.

Fit & Tolerances

My final PETG version was tested with:

• Radial clearance: 0.01 mm

• Top/axial clearance: 0.05 mm

These are intentionally tight tolerances and worked well on my printer. Printer calibration, material and extrusion settings can affect the final fit, so I recommend testing the fit before permanently bonding the original cap.

Parametric Fusion 360 File

A fully parametric Fusion 360 .f3d source file is included, so you can easily adjust the fit without manually modifying the geometry.

Open the .f3d file and go to:

Modify → Change Parameters

Two favored user parameters control the fit:

Cap_Clearance – default: 0.01 mm
Controls the radial/side clearance around the original cap. Increase this value if the fit is too tight.

Cap_Depth_Clearance – default: 0.05 mm
Controls the axial/top clearance. Increase this value if the original cap cannot be inserted completely.

Changing these parameters automatically updates the relevant geometry.

Important

This model does not replace the original threaded Vaseline cap. You need the original cap, which is installed inside the printed shell.

Dimensions of the original packaging may vary slightly between production runs or regions. If your cap does not fit perfectly, use the included parametric Fusion 360 file to adjust the tolerances.