small case with combined living hinge

thingiverse

What sets this project apart is that I managed to integrate a living hinge with another component and manufacture these parts in one go using a dual material printer. I employed Fusion 360 to craft the case design and conducted research online to determine the specifications for the living hinge. By utilizing a dual-material print head, I combined ABS and TPU to create the hinge. Initially, I printed a small test piece to observe how these two materials would interact during printing and assess the need for support material under the hinge. To minimize the requirement for excessive support underneath one of the halves, I designed the two parts to have equal height. The living hinge must be at the same level as the other components for it to function correctly. If you can achieve a print resolution of 0.2mm, the outcome should be satisfactory. Support material is best when made from the same material as the case; otherwise, TPU-based support can be challenging to remove. I have not tested this at lower resolutions, but it may still yield acceptable results.