Rear-View Mirror Air-Freshener Clip (Scan-to-Fit)

Industry:
Automotive Accessories · Consumer Products
Role & Scope:
PRODUCT DESIGN · CAD ENGINEERING · REVERSE ENGINEERING · PROTOTYPING
Tools & Methods:
SolidWorks · 3D scan processing (mesh → solid) · FDM-oriented design · ABS prototyping · Iterative fit testing
Focused clip design aligning scan data with functional fit for 3D-printed prototypes.

Key features:

  • Hidden mounting behind the rear-view mirror
  • Flat sliding slot for 2.5 mm air-freshener blanks
  • Curvature-matched base derived from real 3D mirror scans
  • Double-sided tape interface with controlled protrusion for reliable adhesion
  • Left and right mirrored clip variants
  • Optimized geometry for ABS FDM printing and rapid testing

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The Challenge:

  • The key engineering challenge was to match complex mirror curvature and mounting constraints while keeping the visible freshener flat and hidden.
  • The clip had to follow complex mirror curvature while keeping the air-freshener slot perfectly flat
  • Limited mounting space and strict visibility constraints from the driver’s seat
  • Adhesive mounting required careful control of contact area, tape thickness, and stiffness
  • Multiple mirror models required a repeatable scan-to-design workflow
  • Designs had to be printable, testable, and iterated quickly

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Key constraints:

    • Complex mirror curvature with limited mounting space
    • No visibility from the driver’s seat
    • Adhesive-only mounting (no fasteners)
    • Flat air-freshener insertion despite curved base
    • Need for left/right mirrored variants

    • Outcome:

    • Functional clip design validated through physical ABS prototypes
    • Clean sliding action with flat air-freshener alignment
    • Secure adhesion without visible hardware
    • Scalable workflow established for adapting the design to additional mirror geometries
    • CAD files delivered ready for continued iteration and production planning
    • This clip design can now be adapted quickly for additional mirror geometries with minimal rework, establishing a scalable design process for future variants.

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    What this project demonstrates:

    • Scan-to-CAD reverse engineering for consumer products
    • Designing to real-world constraints, not ideal geometry
    • Mechanical judgment around adhesion, stiffness, and tolerances
    • Practical DFM for FDM prototyping
    • Clear, fast collaboration with non-technical founders

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    Process & Key decisions:

    Scan-Driven Reverse Engineering

    3D scans of rear-view mirrors were cleaned and aligned to establish accurate reference geometry.
    Key surfaces and edges were reconstructed into parametric solids to define reliable mounting boundaries.

    Curvature-Matched Base Design

    The clip base was shaped to follow the mirror curvature while maintaining a fixed offset (~6 mm) so the air-freshener could slide in straight without bending.

    Adhesive Interface Optimization

    A dedicated groove was designed for double-sided tape:

    • Shallow depth to allow tape protrusion
    • Sufficient surface area for long-term adhesion
    • Reinforcement where peel forces are highest

    Left / Right Variant Strategy

    Asymmetrical geometry required true mirrored parts instead of a single universal clip, ensuring consistent fit on both sides of the mirror mount.

    Iterative Prototyping

    Designs were printed, tested, adjusted, and re-released in short cycles based on real-world fit feedback, reducing risk before scaling to additional mirror models.

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    CAD Development & Engineering Proof: