Ford Key Fob Case Front

The key ring part of the key fob for my 2007 Ford Expedition broke.  Ford claimed they couldn't sell me a new key fob without rekeying the entire vehicle.  They said the new key fob and rekey process would be about $350.

I decided to make my own key fob case.  I started with the button side of the case, since I figured that would be more difficult.  After I completed that and moved to create the back of the case, I realized the back contained various codes and IDs that were probably important.  The characters were pretty small, so I didn't want to try and print them.  It turns out, the front case fits nearly perfectly, so I'm still using the original back.

I wasn't going to publish the model, but then a coworker broke the key ring on the fob for his pickup truck and asked if I could print one for him.  With two data points, I decided to publish the model.

Print with “flat” side of case down.  No brim is needed.  0.2 mm layer height was used and is probably necessary to make the “snap” closure function properly.  I used black Overture PLA, and it has held up fine.  The sunlight, pocket abuse, and potential car cabin heat (if you leave your key in your car…I advise against this) will probably cause the case to fail at some point.  Supports are needed for the key ring portion.  I used “tree” supports, and they came free pretty well.  Might need a little post processing for a smooth finish.  I didn't do any post processing, except to remove the supports.

I recessed the buttons further into the case than the original fob, because I don't like accidental button pushes.  If you have large thumbs/fingers, I'm sorry this fob might not be for you.

There are two models, one for four button fobs (Expedition) and one for three button fobs (Truck).