iPhone SE Gen 2 (2020) Composite Case

A composite case made of two materials for the iPhone SE Gen 2 (2020). There is an outer hard shell intended to be made either in PETG, Nylon, or PC, and an inner soft bumper intended to be made from TPU 95A or another flex. They are seperate parts so you don't need a multi-material setup to print this design. The design is sort of based on the OtterBox Commuter case (which I had before but it broke so I decided to try and print my own).

Print the bumper with the large flat face down, however due to the recess for the hard shell, it will still need support. I used a bed of organic supports on this flat face as well as the top surfaces of the holes for the ringer switch, charging port, and speaker/vent. and they came off pretty easily. Print at 0.2 mm layer height with two walls and 5% grid infill.

The hard shell, I tried printing in PLA, PETG, and PA6-CF. I found the nylon worked better, especially after moisture treating it by soaking the case in 90°C water for about 5 mins to further plasticise it. If you can print it, I'd recommend using that, and I'd recommend avoiding PLA unless you have no other choice. You can just use the "case pt 2" file alone if you don't have a multi-material setup as it will have recesses for the icons on the rear (I wanted to make the case themed with some of my favourite games). Or you can combine that model with all the "coloured" files into one file if you want to remove the theming and just turn it into a plain case. You can also do what I did if you have access to a multi-material system and set the coloured parts to another filament in another colour so you get a smooth surface with those inlays. I used a coloured ABS or PETG for these inlays. For print settings, use 0.2 mm layer height, 2 walls, 100% infill with organic supports on the charging port and speaker/vent holes and use 0.8 mm extrusion width on the walls of the part for extra durability with an 0.4 mm nozzle. You can also use the "modifier" files to apply fuzzy skin to just the side walls if you are on BambuStudio or just paint the faces in PrusaSlicer yourself for extra grip if you tend to drop things easily.

This model was created using Fusion 360.