Blu G91S "Otterbox Style" Phone Case

A printable case for this rare model phone.
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updated January 27, 2025

Description

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So, my daughter has this model phone through a service that provides limited access phones for children. Because it's a rare model she's had difficulty finding a case she likes and asked me to help design and print one with her. I drew this myself but the concept is similar to the case I have on my phone:

-The interior is a hard plastic snap together clamshell. It fits the G91s very nicely. I've printed hers in PETG as that's what I had available in the color she liked but ABS would also be a good option I'd think. Because there's a lot of complex geometry requiring supports, I did make use of the multi-material functionality of our Bambu Labs X1c and printed the support interfaces in PLA which makes removal from the print so much easier and cleaner. I definitely recommend taking this approach to preserve details.

-The extrior is intended to be printed in TPU. I used some NinjaFlex Natural because it has a lower durometer than most TPUs at 85, however I think a normal TPU would also be fine.

Also the picture provided includes customization I did for her phone but the files for download are he full design so you can customize yourself if you like.

Update - Version 2.0
Since we've put the case into real world use I received feedback from my client (daughter, ha!). Because these changes require re-printing of every part I'm designating these revisions as version 2.0 but if it is the case that future revisions are made and they only require changing one part I will note that and make that an incremental version. Here is the changelog for version 2.0:

-Updated geometry for interface between ‘caseSleeve’ and ‘caseTop’ which locks much more tightly preventing the outer rubberized sleeve from coming off.

-Relocating of the button cut throughs approximately 4mm towards the bottom for better alignment

-Imprinting a version number into the case bottom so that you can recall which version you have in the event of needing to re-print something or future updates are provided.

Thanks & Enjoy!

Model origin

The author marked this model as their own original creation.

License