Dual Material Phone Packaging

The task is to engineer a 3D-printable cell-phone box that combines a rigid, transparent shell with flexible strap to secure the device inside the package, all optimized for the Bambu Lab platform running an H2D dual-nozzle setup. I will be pairing either Clear PETG or Clear PLA with Regular TPU or its Glow variant, so the design must accommodate any of those two-material combinations without re-modelling.

Priority order is fixed:
1. Structural integrity and long-term durability
2. Cost efficiency in material volume and print time
3. An intuitive lock–unlock mechanism that can be figured out at a glance
4. Overall print duration kept to a minimum

Key guidelines
• Shell walls should resist everyday drops and mild flex yet stay as thin as possible for material savings.
• The exterior shell needs to be transparent so customers can look at the device even from a distance
• Hinges, clips or press-fit gaskets must print in one of the materials mentioned above and mate cleanly to the rigid body during a single multicolour job. Avoid post-processing beyond support removal.
• Geometry must stay within the standard Bambu A1 build volume and the interior of the package needs to have these dimensions: Length 170mm x Width 90mm x Depth 25mm
• All features should slice reliably in Bambu Studio with 0.2 mm layers using stock PETG/PLA and TPU profiles; no custom nozzle swaps mid-print.
• Changes to the attached current design are acceptable as long as they help improve the functionality of the packaging in the order of priority

Deliverables
- Parametric CAD files (STEP or Fusion 360 native)
- Production-ready STL/3MF for both material slots, labelled “rigid” and “flex”
- A brief PDF outlining optimal slicer settings, estimated material usage, and where to place supports
- A short video or GIF showing the lock/unlock motion in the CAD environment

Applicants must show the design they will be proceeding with prior to acceptance
Acceptance will be based on: fit around a generic 6.1-inch phone, ability to withstand a 1 m drop test in simulation, and completion inside four print hours on standard speed.

Once the phone variant is approved, I plan to roll the same design language over to tablets, laptops, and other devices as follow-up milestones.