Stark Varg Charger Case

The Idea

The original charger for the Stark Varg electric motorcycle is a bit bulky. I wanted to design and 3D print a more compact, rugged case for it so it would be easier to take to the track.

The Design

I modeled the new housing from scratch in Onshape as a multi-part assembly. I carefully measured the original charger to make sure all the ports and vents lined up perfectly. For the final detailing, I imported the model into Tinkercad to add the Stark Varg logo, as Tinkercad allows for easy SVG imports and rapid placement of branding elements. On the screen, the design looked great.

What went wrong

I tried to print the parts on my Ender 5, but they were just too big and complex for that printer.

• Warping: Because the parts were so large, the corners started peeling off the bed (warping) during the long print.
• Fitment: The dimensions were slightly off because of the plastic shrinkage—which was worsened significantly by the warping—meaning the internal parts wouldn't fit inside the new case.
• Result: I had to stop the project. It turns out you need a much better, enclosed 3D printer to handle parts this large without them warping and distorting the final dimensions.

Lessons Learned

Design is only half the battle. After spending 4 straight hours designing and refining the CAD models, I learned that for large, functional parts, manufacturing is where things get real. You can't just hit "print" and expect it to work on a basic hobby printer. I’ve kept the 3D models, but I’ll wait until I have access to a pro-grade printer before I try this again.