After reading about some aero gains from Crank covers, I decided to try and 3D print one to fit on my SRAM Rival crankset on my TT bike. The curves and irregular shape/profile of the crank made it difficult to model, so I printed a flat surface, and used heat to mold it to match the profile. It is held on via zip ties.
The design was done using Fusion 360 and a front and and side profile reference image. I printed this on a Prusa MKII.
This was one of my first prototypes. Due to the low melting point of PLA, a heat gun pretty quickly warms it sufficiently to get it to mold into the correct shape.
This was the final version.
EZGains testing results regarding covers and their benefit:
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