3D Printed Key Repair

The key ring hole broke on both my car key and fob. The plastic wore through and finally cracked. I considered drilling a hole through the key but I couldn't definitively determine the transponder chip's location. Instead, I decided to model and print new tops with the key ring hole for both. I sanded off the top of the key and fob on a bench mounted belt sander. Then, I epoxied the printed part using 5min Epoxy. I was concerned about the epoxy bond but it's still holding strong after 2 months of use.

This project affirmed for me the efficacy of using 5min epoxy to bond 3D printed parts to plastic.

Check out the build process photos and cad modeling screenshots below.