I recently got a new camera (a used Olympus OM-D E-M5 ii) and I managed to break off the lever that opens the battery door within a day! This seems to be a very common problem with this camera.

Fortunately, I was able to 3D print a replacement part that's working like a charm! A few reddit comments pointed me to a 3D printed file, which led to a reworked version of that original file that added a key to the barrel of the lever to help the mechanism rotate better without a friction fit.

Original file: https://www.thingiverse.com/thing:4960946

Reworked file: https://www.thingiverse.com/thing:5501023

The print instructions on the original file say "Print in the finest possible setting, layer height 0.05-0.1 mm. Fill 100%." I used that guidance to print the reworked file. It took 13 minutes to bring two copies of the reworked lever on a Prusa MK3S+ at the MIT Metropolis makerspace.

Here's how the two tiny parts looked once they were printed:

To attach the new lever to my camera, I just had to undo the one screw in the middle of this metal plate on the inside of the battery door. As I loosened that screw, the old broken plastic piece fell out and I was able to fit the new lever into its place. The keyed locking piece that the reworked file added was a perfect fit here. After that I just re-tightened the screw into the new lever until it felt secure.

Here's how the camera looks with the new lever in place. It's a perfect mechanical fit and I'm really happy with how it looks. The mechanism feels as sturdy as it ever did and I'm not worried at all about the battery door popping open unexpectedly.

The lever could also be printed in black plastic for a more subtle look, but I kind of like the splash of red. This is also PLA, which is supposed to be not great in cold weather, so if I print more of these levers I'll probably choose a PETG filament.

I really love knowing that I can whip up a new copy of this part if this current replacement ever fails. In fact, I can print up a bunch of these right now and keep them on hand, just in case! For now, my camera completely back in action thanks to this little 3D file from Thingiverse!

For reference, the screwdriver I used to remove the screw holding the lever in was labeled "⊕ 2.0 x 30 mm". I should get a tiny screw driver of that size to keep in my camera bag so I can swap in a new copy of the new lever if this current lever breaks.