CareSense Air saver

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CareSense Air Saver – Description

The CareSense Air Saver is a reusable, 3D-printed protective holder for the CareSens Air glucose sensor, made from flexible TPU 95A. The holder sits around the sensor and provides protection and stability without affecting sensor performance.

Design and Function
The holder is designed to fully cover the adhesive edge of the sensor. This ensures that no tape is applied directly to the sensor or its original adhesive, preventing accidental removal when changing tape. This allows the holder to be easily removed and reused, for example when the tape becomes loose or dirty.

Thanks to the TPU material, the holder is flexible, comfortable, and moves naturally with the body, improving wearability.

Using Tape

• Compatible with Dexcom G7 overpatches (trimmed to size)
• Alternative: cut kinesiology (physio) tape using the included template
• Inner diameter of the template matches the sensor
• Outer diameter indicates the minimum adhesive area (larger is fine)
• In practice, tape typically stays in place for 10–15 days

Preparing the Tape

1. Use the template to trace and cut the tape
2. Remove the backing
3. Place the holder into the tape
4. Apply the tape around the holder
5. Place it back onto the backing until use

Print Instructions

• Holder material: TPU 95A
• Preferably use a smooth PEI build plate
• Dry TPU thoroughly before printing for best results
• Use glue on the build plate for easier release
• Use the modified print profile:
  • Reduced print speed
  • Ironing enabled
  • Modifier block for the top layer
  • Pause to add the support ring

Print Process

1. First print the PLA support ring
2. Start printing the TPU holder
3. When the print pauses: insert the support ring into the holder
   
   
    
4. Resume the print
5. After printing: remove the support ring (reusable)
6. 

Additional Parts

• Print the template in PLA

Post-processing

• Wash the holder to remove any glue residue

The CareSense Air Saver is a practical and durable solution to protect your sensor and extend wear time, while maintaining comfort and minimizing skin irritation.

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