This case was inspired by http://www.thingiverse.com/thing:65810 which is a fantastic gear case by QuentinT. I wanted an iPhone 5 version, as well as the challenge of designing one. In an homage to QuentinT's version I kept the look very similar, since it was already so fantastic and laid out so efficiently. This version also features a soft spring loaded power switch which gives good feedback when clicked.
Update added "deeper" version of the phone case, print whichever version you prefer
Print out one of each part except for the pins.
You will need 3 of 4.5x5 pins
and 3 of 4.5x6.5 pins
and 1 of 6.5x6.5 pins
Sand all the gear faces and surfaces really well. I have included a "Fit Tester" that let me check how the gears were meshing.
SuperGlue the Ridge onto the back of the case. Line it up as best as you can.
Drill out the holes and attach the gears using the pins. 6.5mm diameter for the main gear.
use the shorter 4.5mm diameter pins for gears that are in the "lower layer"
and use the longer remaining pins for gears that rest in the "upper layer" or are thicker such as the 35 tooth geneva gear
- On the Power button, use some superglue on the flat spot opposite of the actual button part. Glue it into the top of the shell so the button protrudes out of the case slightly.
The gears made using my printer needed a bit of break-in. To make that go a bit faster I have also included a gear chuck. Which pops onto the main gear and allows you more leverage when hand turning it. Also it has a hex hole so I could use an electric screwdriver to turn it for me.
This case held onto my phone so solidly that it was a bit hard to get it out the first time. I sanded the inside edges a bit more and now I have a nice secure fit that still pops out when I want without much fuss.
Enjoy, and Thanks Again to QuentinT