Cardo PackTalk Edge Mount for Skydiving

This mount is designed specifically for wingsuiters and skydivers who need reliable communication without the safety risks of traditional mounts. Standard sticky mounts often create a significant snag hazard during canopy deployment. This low-profile TPU housing streamlines the Cardo Packtalk Edge, providing a secure, form-fitting solution that prioritizes safety. Also, this is my first time using fusion 360 and designing a 3d print so it's far from perfect. Think of it as a rough draft to solve a small issue very few individuals have. 

Design Features

• Helmet Compatibility: Designed based on the curvature of a Cookie G3, though the profile is universal enough to fit most modern skydiving and airsport helmets.
• Anti-Snag Geometry: The top cover secures to the base, fully enclosing the unit. All mounting hardware is countersunk to ensure lines cannot catch on screw heads.
• Dual Mounting Options: Use 3M VHB tape for a strong, non-destructive bond, or use the four integrated M3 screw holes if you prefer to bolt the mount directly to your helmet.

Required Hardware

• 4x M3x12mm screws
• 4x M3 nuts
• 3M VHB Tape (for adhesive mounting)

Recommended Print Settings (Bambu Lab / TPU)

This model is designed to be printed in TPU for durability and vibration dampening. For the best results and to ensure the screw holes are structurally sound, I recommend the following settings:

Strength

• Wall Loops: 5
• Sparse Infill Density: 60%
• Infill Pattern: Gyroid

Support

• Type: Normal (Manual or Auto)
• Initial Layer Density: 15%
• Top Z Distance: 0.4mm (helps with easy removal on TPU)

Filament & Speed

• Max Volumetric Speed: 3.0 mm³/s
• Print Speed: 30–40 mm/s
• Nozzle Temp: 240°C
• Bed Temp: 35°C

Note: These are the settings that worked best for my setup. TPU can be finicky depending on the brand, so feel free to adjust your retraction and speeds to suit your specific filament.

Safety Disclaimer: While this mount is designed to reduce the risk of snags, always perform a thorough gear check and follow all manufacturer safety guidelines for your helmet and parachute system. Skydiving and wingsuiting are inherently dangerous activities. Use at your own risk.