Overview
Designed an adjustable seat edge extension for 5th–95th percentile users — no custom machining, no ordered parts. Repurposed a suitcase handle as the sliding extension rail. The critical challenge was the handle: had to hold 250 lb during seated adjustments while clamping onto 80/20 aluminium extrusion. Printed in a specific orientation to maximise layer strength along the load path. Extreme surface finish was required on the bore to grip the rod securely without slip.
