Garmin Varia 515/516 Hard Case

This case is designed to fit the Garmin Varia RTL 515 and 516 bike lights snugly and securely. Unlike the flexible TPU version, this one is printed in PLA or PETG, making it a hard shell case that can be snapped on and off. It took me many iterations to get the fit right — it is not perfect, but it works well and holds the light firmly in place.

I currently use red PLA, which provides a nice contrast and makes the geometry of the case easy to see, but you can use any PLA or PETG filament you prefer.

🔧 Installation Instructions

1. Align the top section of the light with the top of the case.
2. Push the light down into the case until it snaps into place. You might need to gently flex the side legs outward for a smoother fit.
3. To remove it, press through the bottom opening and stretch the legs slightly to release the light.

The side lights and main rear light remain fully visible through the cutouts, so visibility and functionality are not compromised.

💬 Why I Designed This

I created this case after breaking a few prototypes of my Garmin & Wahoo Mount (Easy Support Removal) design where the light would sometimes snap off or get damaged. I needed a way to protect the light without buying a commercial case, so this design was born. The TPU version here is still my personal favorite for its flexibility, but this PLA/PETG variant works well if you prefer a more rigid, structured mount or simply do not have TPU home.