Tesla Model S key fob shell replacement

A replacement shell for the Model S keyfob since Telsa won't sell them to us anymore.
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updated December 5, 2024

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Tesla now lets us re-program key fobs through our MCU, but no longer sells the shell to repair broken or ugly fobs. I had an ugly fob laying around that I was able to replace with a brand new (to me) fob so I wanted to do something with the old PCB instead of just throwing it in a drawer and hoping Tesla would someday start selling the shells again. 

My new fob isn't as…angular…as the factory fob, but it's extremely rugged and functional - just what I needed. The fob prints in 3 parts; the bottom, top and buttons. You can print this out, snap it together and no other work is necessary to have a functional fob. 

Note: the fob requires you solder a 2032 cell to your key. I'm working to find a solution that fits elegantly with replaceable battery but so far they would all add significant bulk.

With that said, I included some QOL items if you so desire:

  • The buttons have a 1mm indent at the base which you can fill with a rubber O-ring/band. This keeps the buttons from rattling around due to tolerances that were necessary to make sure the buttons retracted. 
  • There is space in the bottom to fill with a soft foam or packing material to add to the ‘heft’ of the fob, making the 3d printed part feel more substantial. 
  • There is room for an M3 (6-8mm length) screw and nut - this isn't necessary to keep the fob held together, but adds support where you can fit a keyring. This ensures the metal ring doesn't wear through the plastic over time, while also securing the top and bottom case together so nobody can just pry it apart. 

Tolerances are very tight and force is required to insert the screw, nut and snap the case together. I would suggest printing no lower than a .2 layer height, but I haven't tested higher than 0.16 and my final was printed at 0.08mm. I didn't use supports but had to clean a wisp or two from the underside of the nut/bolt holes. Everything else is print in place with slopes to avoid needing supports anywhere. 

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