Summary

I Have seen others make something similar to this, but for other multitools. I liked the idea, but found no designs for the Leatherman surge, so I designed my own. I hope others can benefit from it as well. By the way, if you are making this for yourself the diamond side of the Leatherman file is perfect for rounding out the final print's rough edges. It gives it a smooth mate finnish. you almost cant tell it was 3d printed!

Print Settings

Printer Brand:

Monoprice

                                            <p class="detail-setting printer"><strong>Printer: </strong>                     <div><p>Maker Select Plus</p></div></p>                                                                                <p class="detail-setting rafts"><strong>Rafts: </strong>                     <div><p>Doesn't Matter</p></div></p>                                                                                <p class="detail-setting supports"><strong>Supports: </strong>                     <div><p>No</p></div></p>                                                                                <p class="detail-setting resolution"><strong>Resolution: </strong>                     <div><p>as low as possible, but I used .06mm</p></div></p>                                                                                <p class="detail-setting infill"><strong>Infill: </strong>                     <div><p>100% </p></div></p>                                                    <strong>Filament:</strong> any, but I used abs any                any                    <br>                        <p class="detail-setting notes"><strong>Notes: </strong>                    </p><div><p>this model can be glued in place, but I designed it to fit tightly so that isn't needed.</p></div>

How I Designed This

I used the canvas feature in fusion 360 to import a photo of the multitool and use it as a reference for design. I then measured and calibrated the image to scale. the design is pretty simple, it's just a couple of curves that were extruded and then rounded out with a fillet.

Leatherman Surge Thumb Stud