Thule Roof Rack Riser

Here’s my photolog of how I solved a sunroof-meets-Thule problem with 3D printing and mold making. My wife’s Mazda 5 has a Thule roof rack mounted on factory hard points. When she tries to open her sunroof, the window hit the rack bar. So, I created a part using the 3D printer she got me to raise the rack up .5 inches. This probably the most useful thing I’ve created with a 3D printer to date. You can see in the photos how the window hits the bar, how I made the silicone mold, and then cast