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Fitness tracker band adapter, designed and prototyped

Two clip-on adapters that let a fitness tracker sit in a sports band, one for each of the client's bands, designed in CAD and prototyped in carbon-fibre PETG.

Client
Thousand Smiles
What it is
A clip-on adapter that holds a tracker in a sports band
What we did
CAD design of two versions, prototypes and test fits
What the client got
The prototypes and the final print files
Start a prototype (opens WhatsApp) Send a brief
Adapter designs, one for each of the client's bands
2
Days from the brief to the approved design
18
Carbon-fibre PETG for the prototypes
PETG-CF

What we brought

  1. What we can do

    Designed around the client's hardware

    Each adapter was drawn around the client's own tracker and band, so it clips into the frame the band already has.

  2. How we look after you

    Prototyped and tried on the band

    We printed each design and the client came to our studio to try it on the band, so the fit was checked in the hand, not only on screen.

  3. What you get

    Files ready for production

    Once the client was happy with the fit, we sent the final print files, ready to order the parts in the numbers they need.

The build

How we built it

5 steps, from the brief to the finished piece. Pick a step to jump to it.

The brief

Step 1 of 5 · 23/01/2026

Part
Clip-on adapter between a tracker and a sports band
Versions
Two, one for each band
Material
Carbon-fibre PETG (PETG-CF)
Our scope
CAD design, prototypes, test fits and the final print files

At Additive Inn, our 3D printing studio in Singapore, we design and prototype small products around a client's own hardware. Thousand Smiles wanted a fitness tracker to sit in two different sports bands. We were to design a clip-on adapter for each band, print prototypes for the client to try, and hand over the final print files.

Design and prototypes

Step 2 of 5 · 27/01/2026

We modelled the first adapter around the tracker and the frame of the first band, a black and grey sports band. The first design went to the client on 27 January.

The second band, a woven strap with its own frame, needed a different adapter. Its design went to the client on 2 February.

  1. First design

    The first adapter, on its own.

    Photo +5 more

  2. Design overview

    The deck set an earlier PLA adapter for a pull-through strap beside Version 1, a slide-in adapter for a semi-circle strap in PLA or PETG-CF.

    Render

  3. Version 2

    A new attachment for a slide-in half-arc strap, in PLA or PETG-CF.

    Render

Printing the prototypes

Step 3 of 5

Both adapters were printed in carbon-fibre PETG on our FDM printers. It is stiff enough for a clip that is pressed on and off, and the tracker sits on the band side, so the material does not rest on the skin.

The carbon-fibre PETG print, close up.

Fitting and testing

Step 4 of 5 · 09/02/2026

The client tried each adapter on its band, with the tracker in place. After a trial on the woven band we refined its clip, making it as firm as it could be while still unclipping by hand, and printed the revised adapter on 9 February.

The first adapter on its band, with the tracker.
The tracker seated in the band.
The second adapter on the woven band.
Fitting the first adapter, step by step.
Fitting the second adapter to the woven band.

The final build

Step 5 of 5 · 10/02/2026

The client tested the revised adapter and approved the design on 10 February, and we sent the final print files for both adapters, ready for the client to order the parts.

The first adapter, finished.

More product development

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