Phone Case
An exploration in customization in additive manufacturing and fitted models
Designed and prototyped a custom, multi-material phone case featuring raised surface geometry and an integrated rotating wheel component. Leveraged additive manufacturing to iterate on fit, ergonomics, material properties, and mechanical performance — balancing aesthetic detail with functional design.
Skills:
Additive Manufadcturing
User Centered Design & DFM/DFA
Tolerance & Fit Design
3D modeling Solidworks
Mechanical Integration
Iterative Prototyping
Process
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Designed a fully custom case in NX to precisely fit my personal device, incorporating raised back-surface geometry and an integrated rotating wheel feature.
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Prototyped on a Prusa MK4 and a Stratasys J826 to validate fit, flexibility, and durability under everyday use.
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Tested multiple shore hardness values to optimize the balance between retention force and ease of removal.
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Transitioned to Stratasys J826 PolyJet printing for the final version, using 85A material for flexible side walls and rigid 100% material for the structural back.
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Tuned peg–wheel tolerances and upgraded from a sliding fit to a bearing-supported interface to improve rotational speed and longevity.
Initial Prototypes
Engineering & Product Decisions
​Precision Fit & Retention
Designed the lip geometry and sidewall flexibility to create a secure snap-fit that prevents accidental release while remaining user-friendly. Shore hardness testing directly informed material selection for durability and long-term performance.​
​Multi-Material Strategy
Used TPU prototypes for functional validation, then leveraged PolyJet printing for higher resolution, color control, and surface finish. Material choice was driven by user experience and aesthetic goals, with an understanding that PolyJet materials trade off long-term durability.​
​Mechanism Integration
Engineered rotational clearance between the peg and wheel, accounting for printer accuracy and material behavior. Adding a bearing shifted the system from a friction-based sliding fit to a more robust mechanical solution.
​Scalability Considerations
While additive manufacturing enabled rapid iteration and customization, I evaluated its limitations in print time and material longevity. For mass production, injection or blow molding would significantly reduce unit cost and improve durability depending on final material selection.
Final Prototype
