Polestar 2 Activity Key Enclosure

The Polestar 2 Activity Key is designed to be disposable. However, if you do not want to throw it away and buy a replacement when the sealed battery runs out (~2 years), it is possible to extract the key electronics, replace the battery and re-house the key in a new enclosure. You can then replace the battery whenever it runs down and choose colours that you prefer or even change them at-will. Save your money.

Disassembly:
I've designed this enclosure to re-use the metal key-chain attachment part. Take care during activity key disassembly to carefully extract this piece (see photos) as well as the key electronics. The key is designed to be submersible up to 10m so it is not easy to get into. The battery is tack-welded to the contacts also so you need to exercise caution peeling them off (I used pliers and a small amount of force).

Printing:
I recommend printing the enclosure shell at 100% infill in the colours of your choice. I've included the Polestar logo star points as part of the design so you can print them in a separate colour and glue them into place should you choose to. I used cyanoacrylate (super-glue) to hold them in place.

I chose to perform a filament swap at a layer change for a dual-colour appearance (see slicer image).

Hardware:
You need 4 x M3 (6mm) bolts/screws of your choice to close the new case. The screws are designed to self-tap into the enclosure bottom screw-holes.

Battery:
This design is built around a CR-2032 battery for longer life than the original battery. Please note, this new enclosure is not meant to be water-proof so avoid getting your new key enclosure wet.

Key recognition:
You will need to reconnect your key to your in-car profile to successfully use it again, follow the Polestar guide here: https://www.polestar.com/nz/manual/polestar-2/2026/article/b8bfcc07242c8242c0a80151779bf46b/

Good luck! I believe in you.