Embedded TPU Zipper Pull Trunk Release Edition

Broken, tiny, or uncomfortable zipper pulls are annoying, especially on bags, jackets, cases, and gear that still work fine otherwise.

This version uses the same embedded-tab system as the original TPU zipper pull, but with a trunk-release-inspired handle shape. The size is fully customizable, so you can adjust the pull width, length, thickness, and embedded tab pocket to fit your zipper tab and preferred grip.

The flexible TPU handle can make a zipper easier to find, grip, and pull, which may be useful for gloves, gear bags, kids’ items, or accessibility-focused repairs where the original pull is too small or uncomfortable.

Pause the print, drop the metal tab into the pocket, and let the final layers capture it inside the TPU handle. No glue, no cord knots, and no loose replacement loop.

Printing Tips

Printing Technology: FDM
Layer Height: 0.2 mm
Perimeters: 4
Infill: 10%
Infill Pattern: Gyroid
Recommended Material: TPU
Supports: No
Support Type: None

Notes:
- Designed to be printed with TPU, but may work with other materials
- I do not recommend printing this directly onto a zipper that still has something attached to it, but it is possible. Do so at your own risk.

Assembly Instructions

Materials Needed:
1x Zipper

Instructions:

1. Measure the metal tab

1. Measure Tab Hole Width: inside of the tab hole, side to side.
2. Measure Tab Hole Length: inside of the tab hole, top to bottom. For round holes, use the same value as width.
3. Measure Tab Loop Thickness: thickness of the metal around the hole.
4. Measure Tab Max Height: tallest point of the tab when it is lying flat.
5. Measure Embedded Tab Length: from the bottom of the tab hole to where you want the embedded section to end.
6. Measure Tab End Width: width of the tab at the end of the embedded section.

2. Set the pull handle size

1. Set Pull Handle Width for the side-to-side grip width.
2. Set Pull Handle Length for the front-to-back grip size.
3. Set Pull Handle Thickness for how thick the TPU handle feels.
4. Set Total Print Height high enough to fully capture the metal tab.

3. Remove the zipper tab

1. Use small pliers to carefully open the slider loop holding the metal tab.
2. Only bend the loop enough to remove the tab.
3. If the tab is crimped in place and does not move, do not force it.

4. Print and embed the tab

1. Slice the model in TPU.
2. Add a pause before the pocket closes over the metal tab.
3. At the pause, place the metal tab into the open pocket.
4. Make sure it sits flat and does not stick above the printed walls.
5. Resume the print and watch the first few moves to make sure the nozzle clears the tab.

5. Reattach to the zipper

1. Let the print cool.
2. Reattach the metal tab to the zipper slider.
3. Close the slider loop carefully with pliers if needed.