Phone Clamp for Walker, Handlebar, Etc.

I created this design for walkers in a retirement home across the street from my high school. The main goal was to achieve an easily usable and printable design that can be inexpensively produced on a large scale.

For this project, you will only need access to Fusion360 to create the design. If you want to print the design, you will need access to a 3D Printer and spare filament. The spare filament pieces are used as threads to connect the pieces. Prior experience with and knowledge of Fusion360 is recommended, as I do not give instructions on the software and solely on the design.

Start by creating a new and blank file in Fusion360. Then, create a new component titled "Clamp". Make sure the units are in mm.

Create a sketch on the horizontal plane line. Begin by creating a center diameter circle at the origin with a diameter of 2.096 mm.

Create a line from the origin that is 3.253 mm long and is at a 57.8 degree angle from the x-axis. Next, select the center point arc tool. Set the first point to the origin and the second to the end of the line, then revolve the arc around 180.1 degrees. The line created in the beginning of this step can now be deleted.

As shown in the reference photo, create a line from the upper part of the arc extending out 2.557 mm at a 32.2 degree angle. Next, create a line from the bottom part of the arc extending out 2.928 mm at a 32.7 degree angle.

This is a difficult portion to give specific instruction on. I have included a photo for reference on where to place the lines, but there is no specific requirement for the final design, as long as it has a somewhat of a hook look to hold the phone. For reference if you are creating your own spline, an iPhone 14 is 7.85 mm thick. The only requirement of the spline is that a 5.516 mm line at an 83.5 degree angle from the beginning point of the spline should line up with the end point of the spline.

For the bottom spline, begin with creating a line from the starting point of the spline that stretches out 1.366 mm at a 75.1 degree angle. The spline has no incredibly specific requirements, only that it follows a similar shape as the reference photo, and that its end point aligns with the endpoint of the line.

On the right-most spline endpoint, create a line that extends out 38.597 mm at a 243.5 degree angle.

Begin by creating a line on the end point of the right-most line that stretches out 3.551 mm at a 206.4 degree angle. Then, on the endpoint of that line, create a center diameter circle with a diameter of 2.096 mm. The line can now be deleted. Then create a center point arc. The first point will be the center point of the circle, and the second point will be at the end point of the line that the deleted line connected the circle to. Revolve the arc around 246.5 degrees.

Create a line at the endpoint of the spline that stretches 0.973 mm at a 146.9 degree angle. This will act as a reference point for a spline.

Create a spline that generally follows the shape of the reference photo. Connect the final point of the spline with the line. Once the spline is finished, delete the reference line.

Create a line that connects the endpoints of the two splines. The sketch should be highlighted blue to indicate it is closed and able to be extruded. If it is not, skim back through the sketch and look for unconnected points and connect them with a line. The sketch might be slightly thinner than showed in the photo, but that will not affect the function of the design.

Select the entire sketch and copy/paste a copy of it. There are 2 legs with the same sketch but different 3D portions, so there needs to be 2 copies of the sketch. This concludes the sketch of the legs

Begin, on the same sketch, by creating a center diameter circle with a diameter of 2.096 mm along the x-axis (red line axis). Create a line from the center point of that circle that stretches straight down 74 mm, and press "X" on the keyboard to convert the line into a construction line. At the endpoint of the construction line, create another center diameter circle with a diameter of 2.096 mm. Finally, create a construction line from the center of the already existent construction line that stretches out to the right 40 mm.

From the top-most circle, create a line that stretches out 3.347 mm at a 54.2 degree angle. Next, create a center point arc; the first point is the center of the circle, the second point is the endpoint of the line, and the arc revolves around 246.5 degrees.

Create a line from the uppermost endpoint of the arc that extends out 3.875 mm at a 23.8 degree angle. Then, from the endpoint of that line create another line that extends 11.5 mm at a 31 degree angle. Additionally, create a third line from the endpoint of the previous that extends out 17 mm at a 47 degree angle. Finally, create a line that stretches straight down to the perpendicular construction line.

Begin by drawing a line from the lower arc endpoint out 1.68 mm at a 31.5 degree angle. Next, create a line from that endpoint that stretches out 10.75 degrees at a 36 degree angle. Then, draw a third line from that endpoint stretching out 16.042 mm at a 127.1 degree angle. Create a final line that stretches straight down to the perpendicular mirror line. Finish this step by giving all four corners on the lines a fillet of 2.5 mm

Select all the objects to mirror and use the perpendicular line as the mirror line. Once mirrored, the sketch should be solid. This marks the end of the base layer sketch. Click finish sketch.

Extrude all 3 objects of the sketch up 26 mm.

From the XY plane, create an offset plane 6.7 mm above the starting point.

Create a sketch on the offset plane. From the origin, create a center diameter circle with a radius of 6.6 mm. The diameter of the circles on the other 5 areas will vary. Use the photo to guide where the circle are and what their diameters are.

Extrude the circles drawn in the previous step. Use the photo to reference which direction the circles extrude. The upward cut extrusion extend 13 mm and the downward extrusions extend 7mm down.

From one of the sketches on the first offset plane, create another offset plane that extends up 12.6 mm.

Create 3 more center diameter cirlces. 2 on both sides of the base piece, and one on the leg. Be specific in which leg the circle goes on (use photo for reference).

Extrude the 3 circles up 7 mm.

Create a new sketch on the XZ plane. Anywhere, draw a 5.2 mm line. Next, draw a 3.675 mm line at a 135 degree angle. Draw a 3rd line to create a solid triangle.

Draw a construction line from the top point of the triangle up 10.4 mm, and draw another construction line perpendicular to the last with a length of 3 mm. Next, drag the 2 construction lines and the triangle together in line with the base 3D object, as shown in the photo. Then, mirror the triangle, using the 3 mm line as the mirror line. Once mirrored, the construction lines can be deleted.

Extrude the 2 triangles 53mm through the base body.

Create a new Sketch on the XZ plane. Then create a triangle the same size as in Step 25. You can use the base piece of the clamp as a reference, as the same triangle was extruded in the base (the solid object in the background of phots is the base piece).

Offset the triangle -0.02 mm. Delete the original triangle afterwards.

Delete the bottom line of the triangle (this will remove the blue highlight, as it is not solid anymore). Next, draw lines from the endpoints of the two sides of the triangle. These lines are .07 mm at a 45 degree angle, essentially extending the lines

Begin by drawing a line straight out right from the bottom right point of the lines that were the triangle that stretches out .5 mm. Next, from the endpoint of that line, draw another line straight down 3 mm. Thirdly, draw a 3rd line from the endpoint of the previous straight out left 12 mm.

Draw a construction line up 26 mm. Then, draw another construction line, starting at the midpoint of the first construction line, that stretches straight out left 16 mm. Next, draw a regular line from the endpoint of the 12 mm line from step 31 that extends up to the 16 mm construction line.

Draw a line from the bottom left point of the triangle straight left .7 mm. Then draw a line from that line's endpoint straight up to the perpendicular construction line.

Fillet the top right, bottom right, and bottom left corners. Use the photo for reference.

Mirror the objects, using the 16 mm construction line as the mirror line. After mirroring, delete the construction lines. Additionally, make sure the mirrored object is highlighted blue, signaling it is solid.

Move the sketch away from the solid reference object. The bottom line of the sketch should be along the origin.

Create a center diameter circle. This portion of the sketch is what will clamp down on the cylindrical part of the walker, handlebar, etc.. The diameter of the circle in this example is 27.5. I would suggest measuring the diameter of the cylinder in which you will attach the clamp to. The only requirement is that when creating the circle, the center must align with the midpoint of the rest of the sketch (green dashed line shown in the photo).

Draw a line from the center of your circle out to the circumference at a 130 degree angle. The length of the radius will based on the size of the circle, but the angle will stay consistent. Then, delete the circle. Finally, create a center point arc. The first point is the endpoint of the line that was the center of the circle, the second point is the other endpoint of the line, and the arc revolves around 270 degrees. After the arc is created, delete the line.

Offset the arc 2.5 mm, then connect the inner arc to the outer arc with two lines connecting each of the sets of points. Then, fillet the four corners by 1 mm.

Draw a construction line from the center point of the arc to the edge of the smaller arc.

Select the entire arc shape. Drag the shape by the right endpoint of the construction line. Connect that point with the left side midpoint point on the rest of the sketch.

Delete the construction line.

Extrude the sketch 30 mm. The intersection of lines divided the sketch into four shapes, so select all four shapes.

One final step! Use the move copy tool to rotate the body on the side shown in the photo. This allows the object to print without support.