Explanation:
For our project, we have decided to optimize the design and 3D printing of an iPhone 7 case that maintains a balance of protection of the device and grip for the user. We feel as though the current market is lacking in a 3D printing option which could be beneficial to the manufacturing of the product. 3D printing phone cases is a great way to explore the customizability and flexibility of the 3D printing machines. For example, we have customized our iPhone case with a similar ‘w’ that is found on the UW-Madison crest.
Preliminary Designs and Manufacturing Considerations:
With this design, we are going to use a multi-material print, where one material is used to print the shell/case of a hard composite and then a flexible material will be used to print the grip. We anticipate using the Ultimaker 3 printer in the Makerspace due to its dual extrusion nozzle that will allow us to experiment with printing with two different materials. Our initial design will utilize the ABS Ultimaker print material for the printing of the phone shell, due to its durable mechanical properties and ability to minimize warping, and it results in the desired matte finish when printed. The TPU Ultimaker print material is a semi-flexible material offered at the Makerspace. It’s often used in applications requiring the qualities of rubber and plastic. However, in our first attempt, we will focus on the design and printing of the outer case before starting on the grip.
Proposed First Print Trial:
We plan to proceed by continuing to develop the CAD design of our phone case, this will include taking measurements with a digital calipers of an iPhone to properly represent its size. After we are comfortable with our design, we would like to print a prototype in order to measure the final dimensions, the amount of warpage, the durability, and the overall quality of the print. From our first prototype, we can make any adjustments to the design and/or settings of the printer for our second iteration. We are initially concerned that the case will not stay on the iPhone due to changes in dimensions from warpage or printer resolution. However, we will focus on improving this after our first print.
As the design stands right now, no support material is necessary as long as the case is oriented in the correct position. After the print is completed, the part may need to be sanded in order to ensure a smooth texture.