American Tourister lock mechanism

thingiverse

The handle locking mechanism on my American Tourister Bon Air 55cm suitcase snapped, refusing to retract at its final level. I reached out to the manufacturer for a replacement part but was left hanging as they failed to respond. Faced with no other option, I took matters into my own hands and designed a custom-made part. Although it's not an exact match, I'm confident that it will fit seamlessly into place. To achieve this level of precision, I used a 3D printer with a resolution of 0.1 mm and 100% infill, which was crucial given the part's small size. However, ABS plastic isn't the ideal material for this type of project due to its stiffness. When inserting the new piece into the chamber, the protruding edge required bending to fit snugly. Fortunately, it withstood the pressure without breaking, but I did notice some signs of stress, which prompted me to take additional precautions. To further reinforce the part, I applied a layer of ABS slurry through the opening on the side, ensuring an extra layer of security.