Client asked for a replacement gasket that fits behind a set of lights on their airstream camper. The old foam gasket had eroded away and the metal on the light fixture had started to corrode the finish on the camper. The client thought that buying a new foam gasket would not solve the issue since the foam would erode away again. The client also wanted to make a change to the gaskets design to better protect the camper.

Client supplied the above image of them pointing to where the gasket should be visible and separate the light fixture from the body of the camper.

Above image: The old gasket is the corroding foam nested in the chrome piece and needed to be replaced.

Video above is demonstrating the difference between the old foam gasket and a new one from the manufacturer.

I modeled a replica of the new foam gasket using Blender 3D. Above is an early version of the modeled gasket using measurements and reference.

Above is my Ender 3 printing the modeled gasket in TPU with the original gasket next to it for comparison.

The video above is testing the flexibility of the TPU gasket replica.

The client wanted the gasket to come up around the sides and cover more of the chrome piece on the light. The light fixtures electrical wiring posed an issue; to replace the gasket you'd have to cut the wiring to the light, thread a new gasket on, then repair the lights wiring. 

To avoid that and make the product more user friendly, I implemented a thin channel in the side of the gasket so the wiring could slip through the channel to the gaskets center. I then made a spacer to wedge or glue in the channel after the wire passed through the channel. 

I created two versions of this model, one for left facing lights and one for right facing lights. The two versions are to ensure that the channel would be on the bottom of either fixture. 

The above image shows the two versions of the gasket for left and right facing fixtures and the spacer that goes in the gaskets channel.

The above video compares the replica gasket to the new gasket with the design changes implemented.

The gasket is installed on the camper and fits snug around the chrome piece.

Final product.