More robust lid design for bike aero storage box

trihardert

Hi everyone,

I've been designing an aero box to go on my TT bike for a while now (actually it's been in limbo for a couple of years). It sits above the bottom bracket, secured by the bottle cage bosses. I printed an earlier version, which fitted perfectly – but the lid flew off mid-race! 

Here's the updated version – but to be honest, I don't think it's really going to work any better: 
https://cad.onshape.com/documents/1a8de2ef61b5b7e3c911bd3f/w/d8c4d8dc5ed9bf9e8f0c0d99/e/7b4047deef56dcb9bd50e787
(See 'Box V5' tab).

If anyone can come up with a method that will better secure the lid, that would be much appreciated! It's going to need to take a bit of rattle and jiggle from British roads!

Cheers,

Tom

TimRice

Hello Tom! It might be helpful to hear more of your design and/or material constraints. Just throwing out ideas but maybe you could use some sort of mechanical fastener like a bolt or some sort of latch. Alternatively you could try magnets or a tighter press fit. Many different methods to try!

trihardert

Hi @TimRice! Thanks for your response – I hadn't even thought of integrating magnets! Perhaps those plus a lip to avoid sliding of the lid would work. Materials wise, I'll be sticking will PLA or ABS and my only other constraints are really the width of the box staying as it is and being able to get fingers inside to fish out the tools and spare inner tube etc that'll go inside it.

josh_deetz

A few thoughts:
A living hinge. I believe it would work with a high-quality 3D print (sounds like that's what you're doing). 
A living hinge with flex filament as the hinge. 
Magnets are a good idea. Rare earth magnets come in every size imaginable these days. 
A fore-aft snap fit lid. VERY rough concept attached. The idea is you need to flex the lid enough to release one of the snaps (front-back). Wind and bumps won't knock it off, only significant flexing of the piece.