The blog blog.tommy.sh has a great post about designing your own potentiometer knobs:
Who needs to buy new potentiometer knobs when you can make your own? Armed with patience, calipers, and a 3D printer, this is quite doable. (Note: this advice will also apply to rotary switches and encoders!)
Why would anybody even want to “reinvent the wheel” when commercial potentiometer knobs are plentiful and readily available?
Control uniformity: A project may use different types of pots side-by-side, each with different dimensions or shaft types, and fitting store-bought knobs may not match. By making knobs that internally match different specifications but have identical outward appearances, you can abstract away the underlying technical differences and have a consistent interface for the user.
Custom position markings: I recently made an instrument with D shaft pots, all mounted at odd angles to the enclosure, and I wanted their “0” positions to point in a way that my store-bought knobs wouldn’t allow. By making my own, I was able to have a custom rotation degree that wouldn’t otherwise be possible.
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Knobs! A good friend has been making knobs for some time; here are some of hers:
Bought my printer based on her demo of same: Dagoma Neva.