Magsafe 1 replacement shell (60W)

thingiverse

This custom shell was designed to allow me to repair MagSafe power adapters where the cable had snapped. The original case is ultrasonically welded together, making it challenging to open without causing damage. While you may get away with opening the case once, attempting a second repair will likely result in cracks or the case breaking apart entirely. The design isn't flawless, so the outer rim of the case doesn't perfectly match the shape of the cable/plug. Nevertheless, this shell works and I've successfully repaired several adapters using it. Note that I omitted the "wings" intended for wrapping the cord, as they don't provide much assistance in my opinion. To print both parts, ensure the outer wall is facing downwards. When handling electronics from power supplies, be cautious as there may still be a charge present even after unplugging them from the wall.