Here is another variation of my gear phone case.
It is a festive Christmas snowman! His green buttons and mittens are now the only thing he is wearing, because the wind blew his hat off.
The body of this case was made with Makerware's newer dual extrusion routine.
This is a multi-part print that is best served with ABS.
All parts are setup to print at .2mm thick slices. .1 will work, but is not necessary.
The STL files names start with the color you should print the parts. The head and body are multiple color parts that you will need to pause after .4mm (2 layers). Then purge and change your colors from green or black to white.
It is best to print all the gears and rivets with at least two sets on the plate, because the first one usually doesn't get a full first layer. The amount of plastic you waste is minimal. I print 3 sets at a time to make 2 complete cases.
The two parts for the case should be merged in Makerware, and printed as a dual extrusion. Load the white in the right extruder, because it prints first. The wind will not show up as well if you let the red print first.
The order I printed the parts is:
Dual extrusion case
Green / White body gear
White small hand gears
Black hat rivet
Black / white head gear
Orange carrot rivet
After you have all the parts, snap the rivets through the gears and into the case. They will be tight in the case! You may need to lay the rivets down on a table and push on the edges of the case from inside. Once you have all the gears in place, make sure the mittens, carrot, and hat are all facing the way you want. Use a mix of acetone and ABS to glue in the rivets from inside. Use two heavy coats.
The phone slides in with the top first, then snap the bottom of the case around it. The gears will be a little stiff at first. Roll the hat gear on your pants, or a smooth fabric quickly back and forth. You will have them spinning freely in no time.