Disclaimer: You can try to print this but the clip keeps breaking on me. I don't think I can make it any stronger. Maybe a different filament.

Herman Miller Posturefit Kit

I have a Herman Miller Aeron chair, size B. It came with a posturefit kit for the back to provide additional lumbar support. The clip that holds it to the chair broke. The replacement part on E-Bay is $100 USD. I made one instead.

This is not the full posturefit kit though. I only made 1 piece (the small outermost plate) and the 2 clips that to hold the assembly together. The assembly is 4 pieces and 2 clips.

When disassembling your posturefit kit, you first need to separate the foam from the plastic. It is glued on so there is no easy way to do it. I took a very thin, flat, and long file, and used that to separate the foam from the plastic.

Then you will see two round rotating clips that hold the 3 plastic pieces together. They do not come out easy. In fact, this is why I made the clip. I broke both when I was trying to remove them. You can try to put a small flat head or tool in the hole and push the frame out to remove the clips. But they are small and weak. If you break them, do not worry. I made the file at uploaded them here.

After that, your kit should be fully disassembled. You can print the replacement part and reassemble.

To reassemble the parts, just follow those steps in reverse. The foam will need adhesion to reattach. I used Gorilla super glue, but double sided tape may be better if you ever need to redo this.

I used a Creality Ender-3 V2 printer. Sliced the file in Ultimaker Cura.

Print Time:

• Both clips takes about 5 minutes each to print.
• The plate takes about 7.5 hours to print.

Print Settings:

• Filament: ABS
  • Printing Temp entire time: 240° C (this is the default value)
  • Build Plate Temp entire time: 100° C (this is NOT the default value)
• For the small plate:
  • I used the "Standard Quality - 0.2mm" profile
  • Infill: 50
  • Add a Support Blocker around the extruding clip, and set "Wall Line Count" to 7
    • See image for more details
    • This extruding clip is badly design and keeps breaking. The walls add extra strength. More than a higher infill.
• For the male and female clip:
  • I used "Standard Quality - 0.2mm" profile
  • Add Support (for the 3 small inner frame flaps for the female clip)
  • Infill: 50