Ok so here's an exclusive look at the almost finished case
I started it in FreeCAD but I grew tired (polite understatement) of its quirks so I rebuilt the whole project from scratch on Onshape and carried on from there. Best decision I ever made too late.
It prints in 4 parts without support, assembles without tools using press fit and snap locks. This test print took about 4 hours on a Prusa MK3s with PETG. The design in 4 parts leverages the textured bed sheet for a nice surface finish on all back and front facing surfaces.
The case is 1.5 Playdate tall - with the extra height at the bottom when held normally - and there's a chin kind of thing that makes the front face flush with the console. This serves several purposes but combined with the added thickness, makes it quite comfortable to hold (even for just playing!).
The chin part hides the USB cable and you can take the PD out and snap it on the other side of the case for some 1-bit selfie action without disconnecting the cable in the process. The camera bump is 0.5 Playdate tall like the front chin, and is not full width so it keeps the PD's power button accessible in this configuration too.
The PD is locked with magnets in both modes (but obviously better secured in regular mode).
The case holds a giant 5000mAh battery that charges the PD in addition to powering the camera hardware. I don't know how long it's going to run, but long. There's a power switch at the top of the case and a charging port at the bottom.
Right now it's possible to easily swap out the sensor board without opening the case so I can test different lens mounts (swapping the entire board). I don't know if that's useful beyond prototyping and I might change it in the final design.
There's one last cool little feature I'm not mentioning here, I'll save it for the next update
I'm quite happy with this last test and I'd say I'm ~90% done with the design by now. I have some small adjustments to make here and there but this is very close to the end goal.
I'll show off the inside in a later post; it might not look like much but it's the most complex 3d thing I've ever designed and it was a lot of fun-pain. I hope you like it!
Now the big question is, what color should I print the final make?