Chipolo ONE TPU Protective Case

I recently purchased a bunch of Chipolo ONE trackers for the family and I love them.  They are, however, a bit on the vulnerable side.  I wanted to print a simple protector that would do the trick, but feel soft in the hand and not be difficult to hang on a keychain or similar.

This design uses 2 components, which I felt gave me the results I wanted with no fuss.  I've personally printed these with standard TPU 95a filament using a .6 nozzle and just left the max volumetric speed set on the filament itself to handle speed regulation.

The first component is a blank for the Chipolo ONE, which I printed with left over PETG.

The second component is the protective case itself.

The blank is used in lieu of supports.  With one or more in hand, I applied a pause in the slicer right before the point where the print job starts to bend inwards to clasp the Chipolo.  During printing at the pause point, I then just put the blank into the print and press continue.  The TPU is then printed around the blank.  PETG's higher melting point ensures that nothing sticks and it pops right out when finished.  TIP(!) Pull the blank out while the model is still warm for the easiest time.  If you let it fully cool, it may stiffen a bit (at least TPU 95a does).

The fit is snug enough to ensure it won't accidentally come out.

The protector itself adds 2mm to the diameter and about 4mm in overall thickness.  You could likely scale the back and opening thickness down a bit if you wish without sacrificing much.