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How to make precision Sugru bumpers for your iPhone!

If feeling confident at your Sugru hacking abilities - try this great precision bumper project for your phone!

Its effective, and looks really great too.

Have fun!

Kit

  • Compression mould
  • 1 x 5g pack of Sugru
  • Scalpel
  • Washing up liquid
  • 8 x m5 by 25mm bolts
  • 8 x m5 wing nuts
  • 8 x m5 washers
  • Menda plastic spludger tool

Step 1

3D printed mound clamped on iPhone

In this guide we demonstrate the process with an iPhone 4/4S. Mould drawings are also available to download for the iPhone 5.

To get your hands on a mould, you can find it open source and free to download from Thingiverse ready to print on your 3D printer.

You can also order your mould directly from Shapeways.

In this guide, we used an SLS print from Shapeways which has a higher resolution than home printing, but is more expensive to print.

To begin with, check that the mould fits together perfectly. Examine the accuracy of the shut lines and sand parts if necessary to make sure they meet properly.

For those who prefer video tutorials, we made one!

Step 2

Paintbrush brushing bumper mould

Apply neat washing up liquid to the sides of the mould that will be in direct contact with Sugru and also on the sides which it will spill out onto (flash). Apply just a thin layer and make sure there is no build up of washing up liquid as this may run on to the phone and stop the Sugru from adhering.

Step 3

Bumper mould on iPhone

Clean the iPhone with paper tissue making sure it is free from grease and dirt.

Pop the iPhone into the mould.

Assemble the mould, insert the bolts, washers and tighten the wing nuts. Tighten so that the mould does not move but do not over tighten as this could break it.

Step 4

Sugru being applied onto mould

Cut open you Sugru and break into 4 equal pieces (one piece per corner)

Break a piece in half and press it into a small flat sausage.

Insert the flat sausages into the gap between the mould and the iPhone on the front and back of the mould and fold over the corner of the phone. By working gradually with smaller pieces we can ensure a strong bond to the phone.

Step 5

Sugru bumper on iPhone

Press and shape the Sugru into a pyramid. Repeat the last two steps for each corner of the phone.

Step 6

Washing up liquid being applied to mould with paint brush

Apply a thin layer of washing up liquid to the 3rd piece of the mould. You are now ready for the forming process.

Step 7

Sugru being moulded on iPhone

The forming process is a three step process, this ensures that you never apply too much force onto the Sugru (this forces the washing up liquid out of the mould and causes problems)

Start by gently pressing the 3rd piece of the mould onto the Sugru. In the image there is a clear gap between the mould parts. At this distance, stop and remove the 3rd piece again.

Step 8

Excess Sugru cut away from mould

Trim away the flash using a scalpel or plastic spludger.

Apply a fresh layer of washing up liquid to the 3rd piece of the mould and press onto the Sugru again. This time pressing it a little further and again removing the flash.

Step 9

Mould parts squeezed onto Sugru

On the third and final time, press the mould parts firmly together.

Step 10

Knife used to cut away excess Sugru

Remove the 3rd piece and trim the remaining flash with a scalpel.

Repeat for each corner.

Step 11

Mould being removed from iPhone

Once all 4 corners are moulded, it's time to remove the iPhone from the mould.

Undo the wing nuts and carefully lift off the the top of the mould. Gently lift it as straight as possible.

Step 12

iPhone pulled out of mould

Carefully remove the iPhone. Again try to remove is as straight as possible.

Step 13

iPhone lying on top of a mug, letting the Sugru cure

Leave the phone resting on something so that the corners are not touching any surface. Leave to cure for 24 hours.

Step 14

Sugru smoothed out with knife

Once cured use a scalpel to clean the excess flash from the phone.

Step 15

All excess Sugru cut away

Cut away any flash line that may be on the corners.

Step 16

iPhone with Sugru bumpers

You should be left with four perfectly formed Sugru corners that will protect your phone from drops! Enjoy!

Step 17

Sugru bumpers being moulded in mould

This is the result from the MakerBot Replicator 2 mould. You can see how Sugru picks up all the detail from the mould. I love this version.