A cover for the fairphone 2.
It's intented to replace the original one which tends to distort after opening the phone for a few times.
This is version #100 now and to celebrate the hundredth change in design I'm gonna call it kind of finished now (change state from "pre-alpha" to "beta").
The most recent version is almost a cheap knock-off of dirkvl's design ( http://www.shapeways.com/shops/funkyotherhalf ) which I tried to avoid all the time with many different failed approaches to make it:
)convenient to open
)as dust-proof as possible
Things I did in a different way:
)the buttons are separate now - this won't ease assembly but reduces material-dependency greatly. It doesn't matter anymore if you print in flexible or brittle materials.
)one problem with dirkvl's design was that the two halves got separated unintentionally quite easy (as a user of the case was mentioning - I didn't try his cover). This and the fact that the gap between the two halves introduce dust to the interior were the reasons I tried to avoid that (actually pretty clever) design. So I didn't find a good solution for it but I added a hook on each half-case's inside that's supposed to keep the cover in place. This works pretty fine but it's still far from a good solution because it adds stress to the phone when attaching/removing the cover (edit: solved with a softer material).
So there's still much to improve. But it keeps getting better and better...
edit: V102 and V103 uploaded.
102: to print it in one piece; not recommended with hard and brittle polymers but doable with rubber-like materials. To reduce the need for support I made the frame a bit thinner and removed the speaker-nipple. Warning - haven't printed it yet... dunno if it works.
103: improved cover to print in two pieces. I've added some kind of dust-sealing at the speaker and changed a few minor details for a better fit.
21.04.2017 - v108: added sleeves for better fitting and less dust intrusion. Plus some further improvements.
02.07.2017 - v113: better mesh, better fitting (was a bit too large), more precise holes for the buttons (the camera button was off a little). This last one was printed in laywood-flex @ 0,2mm.
06.07.2017 - v114: added a logo because it's boring without one.
Flexible materials recommended.
I've printed my most recent cover in "bendlay flex" which turned out to be the best material for this purpose after trying about ten different kind of filaments. You can see it on my pictures (the transparent one). PET-G is ok as well, even laywood works, unfortunately it's not very longlasting. Laywood-flex is great either - looks and feels like cardboard; make sure to print it without cooling and not below 0,2mm layer height to maximize layer adhesion.
The buttons should be printed in a harder material with support though. And take notice of the fact that the buttons only work without issues if you've removed every residues of filament from them and the button-molds of the cover. They are uni-directional... while it's possible to insert them the wrong way around there's usually just one direction they will work alright.
If you want it to be transparent, consider printing at a lower resolution - the bendlay-version was printed in 0,2mm layer height while all the others before were printed in 0,1mm. If your nozzle size is 0,5mm, I recommend printing it without infill (except top/bottom) as this should match the cover thickness nicely.
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