What is it

The metal handle for the locking mechanism on MaxJax is a bit pointy for my tastes. It's exactly at window height for cars parting next to it and craves a recklessly opened door to ease it's blood lust.

To ease my paranoia I made these two part covers that both round the handle and give it a nice cushion

Multi-Material Print (Works)

The 'Outer' piece should rest on top of the 'Inner' piece.
When properly aligned the bottom of the 'Outer' piece should be flush with the top of the base of the 'Inner' piece. (Shown in gallery)
If your slicer supports it I recommend importing the two files as 'one object with multiple parts'

Separate Prints (Should work)

If you print this as two parts it may or may not work. Since there is zero clearance and 3D printers have a margin of error it may not assemble easily.
Scaling up the outer part by a tiny margin is an option if they aren't going together. However, having a file on hand to shave down the inner part is probably a quicker option that will give a snugger fit.

Do NOT scale down the inner model. The inner model is designed to fit exactly around the weird shape of the handle.

Assembly

The fit between the handle and the protector is pretty tight. That coupled with the curved hole means the protectors stay on without glue for a few months.
I recommend having them on for a bit with a dry fit so you can see if you like them and the materials you used.
After that you should glue them as a dry fit will slowly get worn away from use

Print Settings

• Inner
  • PETG: Bambu Transparent (it's what I had lying around)
  • 30% Infill
  • Grid Patterm
• Outer
  • TPU: Bambu TPU for AMS
  • 10% Infill (I wish I had done 5%)
  • Gyroid Pattern

More Thoughts

I wish I had used ABS or something similar. I think the relative brittleness of PETG or PLA may mean that the hard inner core fails by shattering.
Something that fails by deforming or cracking will provide a better worst case scenario. PETG and TPU bond together really well and I figured the ease of printing was worth the trade off. (and honestly any impact that makes the PETG fail will probably have dented the door even with the protector. lol)