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There always comes a time when one of these little buggers falls off, and then begins the annoying process of unwinding grip tape on a road bike. With a handy 3D printer and Autodesk Inventor, this problem is an easy fix. If you are to do this at TechShop like I did, it's even easier. 
The class needed for this project is the 3D Printing SBU and then of course you need a membership. If you wish, TechShop also has  Autodesk Classes for members to get you started in the software! 

Step 1: Measure the handlebars

Using a digital caliper, I measured the inside diameter of the circle to use for reference in the autodesk sketch. What I got was .77in for the interior diameter. This is really the main bit that is needed for design. I also measured the thickness of the metal itself to give a good reference of the total size since I didn't have existing caps to work with. 

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very cool! did you have to do any test with the press fit, or did it work the first time?
It fit perfectly when I installed it, but the cap end was a bit small so for this design that I documented I increased the diameter. As long as the measurements are accurate I wouldn't be worried!

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More by MakerDrake:3D-Printed Plugs 3D-Printed Tapers 3D Printed Handlebar Caps 
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