My strap broke and replacements cost as much as half a spool of expensive filament so i designed a copy.

PRINT AT 100% infill (Unless you know better)

MATERIAL:

I recommend using TPU for this print - its the closest to the original material, some TPU types even specifically state they are good for cold environments.

NYLON is also sometimes used in original straps.

Make sure your material can handle the cold environment and the large stress that can be applied during snowboarding. ABS is likely too stiff when bent, PLA would snap for sure. PETG snapped under impact as you can see below!

Watch out for impact and cold resistance when picking a material

Print at your own risk! 

Don't put yourself in danger with a material you wouldn't trust.

DIMENSIONS:

• 4mm thickness
  • 6 adjustment holes; 71mm first to last
• 8mm holes diameter, except the connecting one which is slightly smaller.
• 25mm width at the long part
• ~33mm at the widest part
• ~153mm total length

My tests:

PETG (fail):

I have used PETG in this case, because I did not have TPU or nylon on hand and needed my board the next day. 

PETG 100% infill print took about 18g of filament

According to AI PETG can handle -40°C without losing its qualities so it should be fine… PETG also has great layer adhesion so I don't expect it to split.

Despite being 4mm thick with 100% infill it remained flexible, although it does not spring back as much as the original. It feels sturdy and soft at the same time. Does not look like there is any permanent damage when bending it in the range it needs. Of course, whatever i can do by hand does not come close to the stress applied while riding.

I made a mistake being impatient and bent it freshly printed warm - that warm bend was slightly permanent. I printed a second one and let it cool first and it sprung back better on the first bend. This could be used intentionally to pre-bend the strap into position slightly.

EDIT: After a day of riding:

DO NOT USE PETG… It broke right at the first ride. Snapped as soon as I hit a small bump in a turn. 

Luckily my binding's front strap was able to keep my foot secure on its own. (Bet those fancy tip holding straps wouldn't manage that)

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Turns out I completely forgot one key parameter of the material:

IMPACT RESISTANCE

• At an impact the PETG lost its flexibility and snapped.
• Looking at material values in retrospective, even ABS has a better impact resistance and would likely have been a better choice.  Still TPU is best and Nylon is likely second, at least from the printer materials mortals can afford.
• Luckily, I had the tools and some paracord (Be prepared when experimenting) and could salvage the rest of the day with what was left of the strap. Nobody even sold a replacement.
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I will try again with TPU once it arrives.

TPU (success)

Looks like it should last forever.

95A TPU is definitely on the softer side. While works just fine, the strap is a bit too flimsy for the rear foot going out of binding - The strap flops around a bit more than usual. It doesn't stretch and holds firmly though.
Comparing to the original 95A is also a lot shinier, I think the original is some sort of harder TPU, probably in the D range. So if you do have the choice, pick the harder matt stuff. Possibly making it thicker could help. (scale in Z) but too thick may get in the way of at attachment screw.

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