Galaxy S25 Ultra energy absorbing rugged case

I designed this case for the Samsung Galaxy S25 Ultra to be drop resistant with minimal bulk.
Features:

• Energy absorbing corners

• Raised edges and corners so the phone can be laid on the screen

• Sunken camera lenses

• Lays flat on both sides

• Optionally additional back corner raisers/ camera bump can be added for extra protection on the back

• Qi2/Magsafe compatible (magnets/steel can be inserted)

• Responsive buttons

The idea is to thicken the corners but leave them mostly hollow and use infill structure as energy absorbing "crumple zones":

Qi2/Magsafe:

The models include variants that are named with "qi2 magnet" and "qi2 steel" to support the following inserts:
magnetic ring:
https://aliexpress.com/item/1005006521276078.html
steel ring:
https://aliexpress.com/item/1005006994459890.html

Add a pause to the print on the layer that the qi2/Magsafe pocket will be bridged to insert the inserts of your choice.
Tip: I recommend using a color change and not a pause since TPU is oozy and the nozzle will loose priming. When doing a color change - the printer will prime the nozzle before continuing the print.

I initially used the magnets since they make it easy to align with peripherals but they cause a little interference with the S-pen which annoyed me (I use the pen a lot more than I use the Magsafe attachments) so I made the steel version (doesn't self align but is more than strong enough).

Tip: if you found a different qi2/Magsafe inserts that you want to use - you can make a model of it load it to the slicer with the standard case and set it to negative volume. or send me details and I'll add another version...

Surface Finish:

I'm printing the case on a textured sheet and using fuzzy skin (though with finer setting than the default) to have a somewhat consistent surface finish. if you also would like to do it - I recommend using paint-on fuzzy skin and use smart fill to only do it on the outside of the case.

Back protection:

The back of the phone is protected as it is with the basic case and the camera lenses are sunken a little under the case's surface. For those who want extra protection and to have the camera lenses higher away from the surface when the phone is on it's back - you can print corner extensions or a camera bump on the back of the case.

Note: camera bump can't be used with the qi2/Magsafe as it will interfere with the accessories placement.
Note 2: the cylinder on the side in the model is used as a priming tower to prime the nozzle after the pause. make sure it is printed before the case elements in the printing order.

Instructions:

1. print the basic case on it's back

2. clean the plate

3. slice the back protection of your choice with a pause before the first layer of the corners (i.e. after the fixture is printed) - ignore warnings of empty layers.

4. print the sliced file

5. snap the case into place over the fixture when paused (note the case orientation - the bump in the fixture is the top of the case - corresponds with the earpiece cutout)

   

6. resume print

   

Recommended printing settings:

• Material: TPU

• Layer height: 0.15mm

• Perimeters: 2

• Fill pattern: Grid

• Fill density: 15%-20% (whichever makes you think will make the corners more effective in absorbing energy. I use 20%)

• Snug supports.
  Please make sure to tune the "top contact Z distance" (Prusa slicer) as TPU is really hard to separate (I use 0.3mm)

• Don't support Bridges: enabled (in order to prevent support material from being generated inside the qi2/Magsafe cavity. if this doesn't work or also disables the supports in the charger/speaker/S-pen cutouts than you will have to use paint on supports)