A protective and functional striker cap designed for an airsoft mortar tube
Airsoft mortars are effective, but the ignition process is awkward. Mortar rounds rely on a small striker surface built into the cap, which means cracking the round open and striking it against a tiny pad while trying not to drop anything. On top of that, open mortar tubes are magnets for water, mud, and debris. None of this makes mortars unsafe, but it does make them fiddly and annoying to use repeatedly during a game.
What was missing was not a better mortar tube, but control at the point of ignition.
The goal was simple. Create a large, obvious striker surface that is easy to use, and protect the open end of the tube from the elements. It needed to stay attached to the mortar at all times, work with slightly different tube diameters, and survive being knocked, dropped, and abused in the field.
Aesthetics were irrelevant. Function and durability came first.
This project marked a turning point. It was the first time an idea went from head to CAD to print to real-world use. Designed in FreeCAD and printed on an open-frame Ender 3, it also introduced TPU as a material choice.
TPU solved two problems at once. It allowed a snug, forgiving fit across different tubes, and it absorbed impacts far better than any rigid plastic would have.
Early iterations failed on fit rather than strength. Flexible materials magnify small dimensional errors, and getting the balance right took multiple prints. At the time, three to four iterations was normal. Today, with better tools and experience, the same part would take one or two.
That learning curve was part of the value of the project.
Nothing broke. The cap developed two stable positions, sealed and rotated for use, enabled by a simple elastic retainer. It stayed attached, stayed aligned, and did its job.
The mortar striker cap became a small but meaningful upgrade that other players quickly asked for.
