FlexCase - OneBlade QP6510

Purpose

I often find myself going on short trips where I try to pack only what is necessary, and my trusty OneBlade QP6510 is always by my side.

Consequently, I had to figure out a design to protect it from the harsh conditions of these adventures.

Design Goals

Having created several enclosures in the past—ranging from simple snap-fit boxes to intricate Print-in-Place hinge designs—I wanted this project to push my boundaries and help me learn new design techniques!

Rather than using a conventional box, I designed a custom enclosure that embraces the capabilities of Additive Manufacturing. The result is a flexible, durable, and stylish travel case—engineered specifically for TPU and optimized for real-world use.

• Designed for TPU: Leverages its flexibility and impact absorption
• Lattice Exterior: For protection and visual appeal
• Living Hinge: Permanently attached lid, so you never lose it
• Optimized Print Orientation: Isotropic mechanical properties and overhangs are easy to print
• Seamless Appearance: Minimal visible connection between the lid and body
• Reusable Design Pipeline: Built with nTop, allowing automatic case generation from any input model
• Print and Go: No extra hardware or assembly needed, it's a simple, all-in-one solution

The long term aim of this project is to create an automatic workflow were a FexCase can automatically be generated given the CAD model of the object to be protected, be it a Philips Beardtrimmer 9000, a banana, a powerbank or a deck of cards.

For this reason nTop, a powerful computational design tool with exceptional capabilities in lattice creation and autonomous parametric design was used. Its design workflow, called a “Notebook” looks more like code block programming than it parametric feature trees in traditional CAD packages. As a result the Notebook is fully reusable.

Design Approach

Initially, the OneBlade was carefully measured with callipers and it was modelled in Autodesk Fusion. 

In the workflow I made in nTop, you import the model of your trimmer and it is automatically wrapped with a textured sleeve to provide extra support on impact. The sleeve is then cut at a height and angle which has been chosen for optimal insertion of the trimmer and overhangs.

The two parts are friction fit which is achieved by removing material from each other in such a way, that the mated surfaces are printed at a ~45deg overhang!

Then the two parts are oriented correctly on the horizontal plane and are connected to each other with a flexible living hinge to ensure you can't lose the lid while travelling.

A mesh is then exported, which can is ready for slicing and printing! Maybe even with Prusament's new and exciting TPU!

Printing 

• TPU Filament
• 2 walls, 15% Gyroid infill recommended, but not compulsory

(The red FlexCase is printed in Creality TPU and the blue one in Ninjatek Cheetah)

Remix and have fun!

If you are a student or academic you can request for a free nTop license. I've included the .ntop file which can be reused for your own application, assuming you have a model of the part you want to make a case for. Feel free to experiment with fascinating lattice structures and cool designs!

Also seeing that large companies like Philips and HyperX, are starting to work together with the 3d printing community, it looks like it's only a matter of time until official dummy models are released allowing the creation of new FlexCases to be almost automatic!

Now go ahead, get a clean shave and bring your OneBlade to extreme adventures!