Blu G91S "Otterbox Style" Phone Case

Update, March 2025 - Well wouldn't you know it, a handful of weeks after my daughter and I finished designing this case for her phone, my ex-wife told her it was time to upgrade her phone and pass her old one along to her younger brother. Lol. So: we did an updated case sleeve for him. He's into Harry Potter and so he asked for the “Ravenclaw crest” on his. I thought I'd upload his design in case anyone is interested in it. It fits along with the other parts already uploaded so no updates required there.

So, my daughter has this model phone through a service that provides limited access phones for children. Because it's a rare model she's had difficulty finding a case she likes and asked me to help design and print one with her. I drew this myself but the concept is similar to the case I have on my phone:

-The interior is a hard plastic snap together clamshell. It fits the G91s very nicely. I've printed hers in PETG as that's what I had available in the color she liked but ABS would also be a good option I'd think. Because there's a lot of complex geometry requiring supports, I did make use of the multi-material functionality of our Bambu Labs X1c and printed the support interfaces in PLA which makes removal from the print so much easier and cleaner. I definitely recommend taking this approach to preserve details.

-The extrior is intended to be printed in TPU. I used some NinjaFlex Natural because it has a lower durometer than most TPUs at 85, however I think a normal TPU would also be fine.

Also the picture provided includes customization I did for her phone but the files for download are he full design so you can customize yourself if you like.

Update - Version 2.0
Since we've put the case into real world use I received feedback from my client (daughter, ha!). Because these changes require re-printing of every part I'm designating these revisions as version 2.0 but if it is the case that future revisions are made and they only require changing one part I will note that and make that an incremental version. Here is the changelog for version 2.0:

-Updated geometry for interface between ‘caseSleeve’ and ‘caseTop’ which locks much more tightly preventing the outer rubberized sleeve from coming off.

-Relocating of the button cut throughs approximately 4mm towards the bottom for better alignment

-Imprinting a version number into the case bottom so that you can recall which version you have in the event of needing to re-print something or future updates are provided.

Thanks & Enjoy!