From Clumsy Clip to Custom Car Mount: How 3D Printing Solved a Real-World Problem

At CADimensions, staff enjoy perks such as access to the CADFABLAB and a network of experienced SOLIDWORKS users. I recently purchased a magnetic car vent clip to keep my phone visible while navigating, but the clip’s weak grip meant my phone repeatedly fell under the seat. By the third incident, I was ready to abandon the purchase—until I found an engineer instead of a trash bin.

I asked my brother, Tom DiLaura, to take a “universal” part and create a custom solution for my car. I handed him the vent clip and the keys, and after confirming the clip wasn’t installed incorrectly, Tom pulled out a notebook, measured the console, and began sketching a tailored design. By evening he had a SOLIDWORKS model that would fit the center console and sent me a screenshot for approval.

Once I approved the design, Tom printed the first prototype on our MakerBot Z18. I tested the fit: the vent clip sat in the cavity, but the edges were too rigid to conform to the console. I returned the part with my notes and car keys for a second iteration.

My involvement grew, and we discovered the power of rapid prototyping. We added a lock bar inside the cavity to secure the vent clip, and Tom refined the surfaces to match the car’s curves, adding recessed pockets for double‑sided tape. Trimmed top and bottom edges reduced space usage and improved fit. Though the part’s complexity grew from one feature to ten, the result was a reliable, custom mount.

With prototypes complete, Tom added cosmetic fillets and exported the final file to the uPrint in the CABFABLAB. The finished part was sturdy, visually appealing, and functionally sound.

Tags: CAD Fab Lab, Consumer Products, Parts, Solidworks