Designed another phone-case (given that its been 4 years since the last one), can you tell I like spaceships!?
Anyways, feel free to download and make your own, and check out the sketches and process of design below.
Disclaimer: The printed parts in the cover picture were professionally printed and ordered through Shapeways, using the stronge and flexible plastic option. The details in the prints were too much for my little home-made printer
Initial design sketches, right is the original sketch from 2015 for Samsung Galaxy S4 phone, left is the adapted design to fit my newer Nexus 5X
Initial Design and Sketches
I originally designed the case in my engineering notebook with a few sketches of how it would look. I used the following image for reference: https://www.howitworksdaily.com/wp-content/uploads/2015/05/6938210-space-shuttle-photos.jpg
After being unsuccessful at locating a usable and accurate CAD model of the Nexus 5X I took to my phone with a pair of calipers and made a really basic stand in with which the case models would be built around and tested.
Following that I created two cases which would interface with each other, one fitting over the phone, then another fitting over the first case. From there I layed out how I wanted portions of the design to align through the various levels. Knowing my phone was black I wanted to be able to use it in combination with orange and white.
Once the case designs were complete I took to sketching out the design and making cuts where they needed to align.
I worked primarily in assembly mode in Solidworks where I could edit the part based on how it would look with the phone and additional case, which made visualizing much easier.
Once all was done design-wise I uploaded it to Shapeways, and continued to make various tweaks based on wall-thickness, and a few fillets of concern before it was ready to be ordered.
Transferring the general sketch to the inner case
The final put together assembly in Solidworks before uploading stl files and ordering printed versions