Clever Geek Handbook

What does the production of Flipper Zero cases look like from the inside

Mold for one of the Flipper Zero parts
Mold for one of the Flipper Zero parts

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Part cannot be removed from the mold if it is improperly designed
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GPIO hole pins block removal of the part from the mold, so the needles are movable and retracted before removal
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Top cover mold
Bottom cover
Screen cover
Buttons

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Flipper Zero Bottom Cover Mold Assembly
- Flipper Zero
Flipper Zero Bottom Cover Mold (side view). Electrical connector visible
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Flipper Zero.
Flipper Zero.

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Too deep ejector pin mark on the screen edge, too thin plastic there
Too deep ejector pin mark on the screen edge, too thin plastic there
Visible sink mark between pogo pin holes
Visible sink mark between pogo pin holes
Air trap on internal ribs which influences their shape
Air trap on internal ribs which influences their shape
The Lightpipe doesn’t sit tight when assembled to the Display housing
The Lightpipe doesn’t sit tight when assembled to the Display housing
The part doesn’t match the drawing which leads to assembly failure
The part doesn’t match the drawing which leads to assembly failure

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First covers

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Telgeram- @zhovner_hub







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