iPhone 15Pro Max Flexible Case

This is a flexible case for the iPhone 15 Pro Max with extra support for the corners.  We have several hundred iPhones where I work, and whenever one is returned to us because of a cracked screen it is most often caused by the phone being dropped on one of the corners.  

I recently updated my personal iPhone and wanted to design a flexible case, as I did for my previous model.  I have learned a lot from using my old case for a couple of years and made some improvements to the design of this one.  I also added corner supports.

Some other design goals were to eliminate the use of supports, make the case easy to install and remove, and make it a little thinner than my last design.  Additionally, the case stays on even though it is easy to remove.

The first image is a render done in Cinema4D with the Arnold renderer.  The second picture is of an actual print using Fillamentum Flexfill 98A Powder Beige and the last picture using an inexpensive soft TPU.  The Fillamentum Flexfill 98A printed perfectly using the profile in PrusaSlicer.  All I did was lower the bed temperature to 35C.

Printing

This is designed to be printed with TPU.  However, harder TPU is better (and often easier to print) than soft TPU.  I recommend using a TPU with a Shore-A hardness of 98 because this harder TPU will make the corners less flexible offering better protection when dropped.  No matter what TPU you use, please make sure your TPU is DRY before printing!  I used a 0.2mm layer height, 2 parameters, 5 top layers, and 4 bottom layers.  I left the infill at 15%, but this is meaningless since there is very little infill on this print.  A good starting point for me while printing TPU is printing at 230C and on powder coated bed at 35C.  No supports are needed, but you can add supports to support the inside lip.  I did not use supports and it printed fine, but supports can help a little.  The print is properly oriented for printing.

One last note on printing.  Please make sure you have your printer setup for a good first layer.  Normally I design a slight chamfer on the edges that are on the print bed.  But I was going for a look that matches the iPhone 15 Pro Max, so I did not make a chamfer on the edges.  The look is great, but please make sure you have your printer dialed in properly, or have a printer that takes care of the first layer for you.

As with most of my designs, I designed this for myself but I am making it available for everyone to use.  Please let me know how it works, and if there is anything that I can do to improve this.  And of course, good luck with all your 3D printing!