iPhone 15 Pro Magsafe Wallet Foldout Case

This case was designed with onshape.com and printed with 98A TPU on a Prusa MK3s.

SLICING

By far the hardest part was removing TPU supports. You can bezel around the camera looks very rough. The whole case looked that way until I figured out a decent strategy for supports.

I used PrusaSlicer with the AmazonBasics TPU profile and these changes:

• 0.2mm Quality
• 80% infill
• Organic supports
• Supports everywhere
• 40° overhang threshold
• 0.2mm top contact z-distance
• Top/Bottom interface layers: 3
• Speed: 20-35mm/s
• Nozzle 210°

Organic supports with thick interface layers was key to pulling supports off in a clean way.

Case - printed with the camera bezel facing down. In hindsight, i'd print it on a raft of organic supports to make the bezel easier to remove supports.

Wallet - printed upright with the bottom of the case facing down. This allows the hinges to print clean. Large brim to ensure plate adhesion.

PRINTING

I tried standard TPU but it was too flexible. PLA was too breakable. PETG was too rigid. I ended up using 98A hardness TPU (link below). TPU is hard to print, but utterly unbreakable. I've yet to try nylon.

Tip: you absolutely have to dry brand new TPU. I went through an entire spool with prototypes. I printed from the second pool straight out of the package and it was insanely stringy. I dried it overnight at 50°C and it was a massive difference.

ASSEMBLY

I used a drill with a tiny bit to clear out the hinges. Then i bought a 100mm x 1.5mm steel rod (link below) and cut it to size for use as a hinge.

The case has two magnets plus a magsafe ring magnet which hold the flap closed with a very satisfying snap. You could probably do one or the other. I used super glue gel which worked extremely well on TPU.

By the way, in an older design, I used Tetrahydrofuran (THF) for connecting TPU parts that were printed separately. It did not work well for 98A although it does dissolve the TPU so it's probably better for cleaning up rough supports.

ADDITIONAL PARTS

TPU 98A Filament:

https://www.amazon.com/gp/product/B09229WKY3

Hinge (1.5mm steel rod):

https://www.amazon.com/gp/product/B07KY8XJQL

Magsafe Magnet Ring:

https://www.amazon.com/gp/product/B09VDMVKPF

Round Magnets (Round, 5x2 mm):

https://www.amazon.com/gp/product/B09SW9BQ2D