Summary

I took the original design and thickened the outer edge for strength.
I also made the gap the band fits through smaller (4mm).

I made these changes for peace of mind as I work at extreme heights as a Wind turbine Technician.

The clips didn't clip in as securely as I was hoping on my specific model of hardhat so I also used a few drops of superglue as well.

Edit: the clips have stayed securely on my hard hat as of late 2023 with almost daily use

Print Settings

Printer Brand:

Creality

Printer:

Ender 5

Rafts:

Yes

Supports:

No

Resolution:

0.2mm

Infill:

100

Filament:

Spool 3D PLA Black