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KIND OF A BIG DILL
Work/Product design // Design for printing

A better grip on the torch.
Two parts, two sizes.

A printed handle for WP-17 and WP-26 TIG torches. A ducted core slides onto the torch and a diamond-knurl grip sleeve threads onto it. Grooves in the core become 16 air ducts once the sleeve is on. Fit-check coupons print first, and the whole thing ships as a print pack with instructions.

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Torches
WP-17 (150) and WP-26 (250)
Length
5.00 in
Grip
1.500 in over the diamond knurl
Parts
Core plus a threaded grip sleeve
Cooling
16 air ducts, head to tail
Status
Prototype P1, print pack released
Case study

Why the handle exists

The challenge

Make one handle design that fits both WP-17 and WP-26 torches, is sized for a gloved hand, and lets air move through it instead of trapping heat around the grip.

What I did

Split the handle into two parts: a core that slides onto the torch and a grip sleeve that threads onto it. Grooves in the core turn into air ducts once the sleeve is on. One design, two cores, sized for the WP-17 and the WP-26.

The result

Prototype P1 with a full print pack and instructions. Fit-check coupons come first so a bad fit costs a few grams of filament, not a full handle.

The part

Three features that do the work

TIG torch handle exploded: core and grip sleeve with numbered callouts
Core and sleeve from the P1 print files, sleeve pulled back to show the ducts.
1

Finned head

The flange at the torch end is the stop for the sleeve. The fins behind it leave windows open so air can get into the ducts.

2

16 air ducts

Grooves run the full length of the core. With the sleeve on, they close into ducts that carry air from the windows at the head out the tail.

3

Threaded grip sleeve

The diamond-knurl sleeve slides on from the cable end and threads onto the tail of the core until it seats against the finned head.

Inside

Where the air goes

Section through the TIG handle core and sleeve
Section: torch bore, ducts between core and sleeve, and the thread at the tail
Illustrative air path through the TIG handle ducts
Air in at the head windows, down the ducts, out the tail. Illustrative, not CFD
Sizes and fit

One design, two torches

150 and 250 TIG handles with overall dimensions
150 fits the WP-17, 250 fits the WP-26. Same 5.00 in length and 1.500 in grip
Fit-check coupons: stem gauge and thread coupons
Stem gauge and thread coupons print first, then the full parts
Process

Small prints first, then the part

  1. 01

    Measure

    Torch stem and head measured for both sizes, WP-17 and WP-26, so each core slides on with a snug fit.

  2. 02

    Model

    Core and sleeve modeled as a pair: finned head, ducted body, threaded tail, and a knurled sleeve sized for a gloved hand.

  3. 03

    Coupons

    A stem gauge and two thread coupons print first. They check the fit on the torch and the thread engagement in minutes, not hours.

  4. 04

    Fit check

    Only after the coupons pass do the full core and sleeve print, then go on the torch for the fit checks.

  5. 05

    Release

    Print pack: build plates, individual STLs, STEP files and assembly instructions for both sizes.

Your product

What this means for your project

For makers and shops

Grips, handles and adapters that fit the tools you already own.

Tell me the tool and what bugs you about it. I measure, model the part around it, and send fit-check coupons before the full print so the fit is right the first time.

For product companies

From idea to a print pack you can hand off.

Multi-part designs built for printing, size variants from one model, test coupons, and a release package with plates, STLs, STEP files and instructions.

Got a tool that needs a better handle?

Send me photos and what you want it to do. I review every request myself and reply within 2 business days.

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