Flipper Zero case

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updated 15. 8. 2023 | published 15. 8. 2023

Summary
Finally a fixed Flipper Zero case with reinforced hinges + a version of the
top cover for the WiFi module.

Gadgets > Computers

Tags: tool case zero hacking flipper

I was tired of wasting filament and time for printing several different
models of this case which had very weak hinges and broke instantly, so I
fired up Sharpr3D and fixed the hinge issue myself. There is also a clip to
close the case safely, but personally I don't use it.
REQUIRED HARDWARE: 2x M3x25 mm screws with a flat head, 4x M3
nuts.
PRINTING INSTRUCTIONS: To print the text in a different color on a
regular printer (no MMU) you can exploit a feature of PrusaSlicer that
automatically centers imported models to the middle of the printing
surface. So make sure to import the text STL and the top lid STL at the
same time, they will allign perfectly. After that you can select both text
and top models and move them simultaneously to the side of the printing
surface so that the bottom part will fit as well and you will only have to
print in 2 steps. After you put all of the 3 models in your slicer with the top
part aligned with the text, you can hide or delete the case parts so that
only the text part is in the slicer. Export this GCODE to your SD card/flash
disk. Then unhide or bring back the case models (personally I deleted
them in slicer and after exporting the text just pressed Ctrl+Z two times to
bring them back into the same position). Delete the text object (since it
will be printed in first step) and export just the 2 case parts to your SD/
flash disk. I used PLA for both. Once you put the SD card/flash disk into
your printer you need to print the text first, immediately after the printing
finishes preheat the printer manually to your filament of choise so that the
heatbed will stay warm and the text will not release itself. Then change the
filament to a different colour and print the second part with the case. No
additional slicer settings needed (OG mentioned XY compensation, I found
out you dont need it at all). Use paint-on supports for the hinges of the top
part of the case (mainly below the hinges that overhang) - check the
screenshot below on how I did mine.
And last of all - don't worry, it seems difficult, but really isn't. OG posted a
lengthy YouTube video on how to print 2 different colours in a single layer,
I figured I'd just explain it here so that you don't need to watch the entire
video.

WHY DIFFERENT TOPS: There are 2 different versions of the top part of
the case. File top-strong.stl is with a square opening for the foam with the
charging cable, while wifi-top-strong.stl is a version that fits perfectly the
WiFi external module for Flipper.
INSTALLATION: Use the original foam inserts that came in the cardboard
box with your Flipper, gently screw in the screws for the hinges and put a
nut or 2 on the other side. I bought M3x25 mm screws and they were
sticking out ever so slightly, that's why I put 2 nuts on both sides.

Let me know if you like the model and make sure to post a result of your
print :)

UPDATES:

15th of August 2023: Per your requests I have uploaded the wifi module
case/chassis. Look for other downloads below and the file name
wifi_chassis_minimal.zip, inside are the 2 parts of the case. Mine is printed
with a transparent resin on a SLA printer, the 2 parts are friction-fit
together, no screws needed. I recommend printing a at least 2 pairs if you
go for resin, cause it may crack when putting together, it’s a very tight fit,
might need a bit of sandpaper prep and a bit of force. It’s not my original
model, but I could not find the model I have downloaded neither on
Printables nor on Thingiverse, so I have uploaded the STL files, if you know
the author, let me know, I will post a link and delete the files.

This remix is based on

 Flipper Zero Case
by TruTech

Flipper Zero Wifi Case

by QuandaleTheInventor

Model files
flipper-text.stl

wifi-top-strong.stl

top-strong.stl

bottom-strong.stl

Other files
wifi_chassis_minimal.zip
License 

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