Mustang Mach-E Oversize Phone Charging Mat

The Mach-E Charging Mat

After recently purchasing a new 2026 Mustang Mach-E I noticed the wireless charging pad in the car came with a rubber mat which interfered with plus-sized phones in cases. The issue here is that when it comes to wireless charging, the efficiency is heavily impacted by any misalignment between the two coils (I.E. inside your phone and on the charging pad itself). I immediately set out to reverse-engineer the stock part so I could redesign and print a superior replacement which would not impact the charging efficiency.

This new charging mat offers two main advantages: it easily fits oversized phones, and it is slightly thinner which is better for charging efficiency. Included are three main models:

• A basic, low-detail model that includes no decorative flourishes or texture

• A pretty, high-detail model that includes decorative flourishes but no texture

• A pretty, high-detail model that includes decorative flourishes and a reverse-engineered recreation of the stock mat's texture applied using BumpMesh

The textured mat obviously isn't smooth like the injection molded stock part, however the surface feel is very similar. Big thanks to CNC Kitchen for their handy web tool BumpMesh (https://bumpmesh.com/). Included is also two .ZIP files, one containing the raw displacement maps for the texture (including an unused "waffle" texture I created), and the other containing the settings for BumpMesh. Simply rename the archive from ".zip" to ".bumpmesh" and you can load the project in the online tool!

Print Recommendations

Material

For this model 95A TPU is fine, however if you have any stiffer TPU or FLEX filament, I highly recommend that instead. Highly stiff filaments (PLA especially) are not recommended since the holder will get hot and may wiggle around or rattle when driving.

Settings

Since this model is very flat and relatively thin, anything less than 3 perimeters and 25% rectilinear infill is not recommended. I printed with 6 solid top and bottom layers as well to increase the print density and give it more weight + stiffness. if printing with the BumpMesh-textured top surface, enable variable layer height and paint a high detail region covering just the textured layers in order to get the nice textured feel. At a typical 0.2mm layer height with the correct adjustment, you should see a single line extrusion covering the tops of each of the hex patterns like shown in the image below:

For any post-processing, you may want to briefly touch the surface of the hex texture with enough heat to melt away any stringing, however this is more printer dependent. If you do this, you might want to lay the mat against a flat, cold surface to reduce the chance you accidentally blow a hole through the part due to its thinness. The print time on my XL was about 20 hours, however my TPU setup is not ideal so your time may vary.