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:
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.
The author marked this model as their own original creation.