TSATool

thingiverse

The TSATool was created as a convenient way to store and use replicas of common Transportation Safety Administration (TSA) "master keys" (TSA002 & TSA007). Critics often dismiss printed keys as not strong enough, but now it's clear that the real threats are the conditions in a user's pocket or bag. With the TSATool's folded frame, you can toss it into a bag and take it anywhere. The complete website for this project is located at TSATool.com. Building Bill of Materials Assembling the TSATool requires the following parts, aside from prints of each component: M4X15mm Cap Screws (x2) M4 Washers (x8) M4 Nut (x2) These parts can be sourced from Home Depot for about $4. However, they may cost less in areas where metric hardware is not rare. Note: You can skip using the M4 washers if you print two copies of "optional_spacer.stl," though metal washers provide a smoother action. Assembly Assembling the TSATool is simple. After printing all parts, snap the two M4 nuts into hexagonal sockets on both sides of the tool, then thread the screws into their respective sockets. When the screws pass through plastic, add one washer, the printed key, and finally three more washers. This exploded render shows how each side should be assembled: Exploded View Once both sides have installed washers and keys, you need to line them up and screw them together. I find it easiest to do one side at a time, ensuring only the initial screw is inserted a few turns so you can rotate the sides for alignment. Note: The goal is not to crank screws all the way down; aim for tight enough tension on the keys but loose enough to rotate without bending. TSA Key Project The housing design is new, while the keys are modified from the TSA-Travel-Sentry-master-keys project. These key models were originally released as a proof of concept by Steven Knuchel (Xylitol), which I then refined into workable keys with input from testers and experimentation. As the TSATool is a derivative work of "TSA-Travel-Sentry-master-keys," it inherits the Creative Commons Attribution-NonCommercial 3.0 license; this means the TSATool cannot be sold or used for profit.