REV Driver Hub Protective Case — FTC Robotics

Overview

I wasn't really happy with the Driver Hub cases I found online, so I decided to design my own specifically for FTC robotics.

The goal was to make something that could provide substantially more protection from drops while still allowing the Driver Hub to be used normally during a match or in the pit.

The case is designed around the REV Driver Hub (REV-31-1596).

Protection

The main version combines a rigid PLA outer shell with an integrated TPU impact liner.

The TPU is printed directly as part of the case using a multi-material printer. It remains in continuous contact with the Driver Hub rather than leaving an air gap between the Hub and the case.

The PLA shell also uses gyroid infill to help distribute impact energy throughout the structure.

The corners are reinforced to provide additional impact protection while also housing the screw holes.

The design was created with drops of approximately 7 ft as a design target. This is a design target rather than a guarantee that the Driver Hub will survive every possible impact. A direct impact against a hard edge, particularly around the screen, can still damage the Hub.

Two Versions

PLA + TPU

The primary version uses:

• PLA outer shell

• Integrated TPU impact liner

• Gyroid infill

• Two printed pieces: base + cover

• Multi-material printing

An AMS or another filament-switching system is required for this version.

The TPU liner is printed directly into the part during the print rather than being a separate piece that needs to be installed afterward.

Full TPU

A second version uses essentially the same overall geometry but is printed entirely from TPU.

This provides an option for teams that don't have a multi-material printer.

Supports are recommended for the TPU version.

Features

Driver Hub Access

The case is designed so the Driver Hub can still be used normally while installed.

The following remain accessible:

• Screen

• Buttons

• USB ports

• Power connector

• Other external ports

The internal battery compartment on the bottom is not directly accessible while the case is assembled.

If you normally power your Driver Hub through an external power source, this does not prevent normal operation.

A separate battery-access version is also planned.

Assembly

The case uses 4 M4 screws.

Recommended hardware:

• 4 × M4 × 15 mm screws

The screw holes are designed to work with approximately M4 × 10–20 mm screws.

The printed screw holes are 3.6 mm diameter, allowing the M4 screws to thread directly into the printed material.

No nuts, threaded inserts, or other hardware are required.

The Driver Hub slides into the bottom portion of the case, and the top is then secured using the four screws.

Tools are required to remove the case.

Team Customization

The bottom of the case has an area specifically intended for team numbers, names, or other identification.

You can add your own text directly in your slicer.

For example, my demonstration version uses:

Duster 23545

This personalized version is only shown as an example. The downloadable model does not include my team's personalized text.

To customize it, add your own text to the bottom of the case in Bambu Studio or another slicer and keep it shallow enough that it does not interfere with the case.

You can also change the text's color if you're using a multi-color/multi-material setup.

Dimensions

Overall dimensions:

• Width: 3.935 in

• Length: 5.867 in

• Height: 1.150 in

Screen opening: approximately 4.350 in

Screw holes: 3.6 mm

Printing

PLA + TPU Version

• PLA + TPU (I used Bambu Labs AMS-TPU because normal TPU and AMS' are not friends)

• Multi-material/filament switching required

• AMS or equivalent recommended/required

• Supports required

• Normal layer height and standard material settings can be used as a starting point

The TPU is integrated into the print rather than printed as a separate insert.

Full TPU Version

• TPU

• Supports recommended

• Normal layer height

• Use settings appropriate for your specific TPU

The model should be adaptable to other printers capable of printing the required materials and handling the necessary material changes.

Design Notes

This is a V1 design, so feedback and suggestions are welcome.

The case was designed specifically around the REV-31-1596 Driver Hub and the needs of FTC teams. If you print one, I'd especially like to know how it performs during normal team use and whether there are any areas that should be improved in a future version.

If you make one for your team, I'd love to see it!