Step 1: What you'll need
For this project you'll need the following:
-a computer with Solidworks or similar CAD software
-calipers or a ruler
-access to a MakerBot or a similar 3D printer (I used a MakerBot Replicator)
Step 2: Measure the iPhone width
First, measure the width of the iPhone with the calipers or ruler. My iPhone 3G measures 2.448 inches wide. Rounding up to 2.5 inches is suitable for our purposes. Write the 2.5 inch width measurement down for later reference.
Step 3: Measure the iPhone thickness
Next, measure the thickness of the iPhone with the calipers or ruler. My iPhone 3G measures 0.439 inches thick. Rounding up to 0.45 inches is suitable allowance for the thickness of the phone. Write down 0.45 inches thickness for referencing later.
Step 4: Create the side profile sketch in SolidWorks
Now you can translate the measurements you just took to build an accurate SolidWorks model.
Start up SolidWorks & open a new part file.
Select the Right Plane & create a new sketch.
Sketch the side profile of the stand using the your 0.45 inch thickness measurement & the sketch here as reference.
Step 5: Extrude the profile sketch
Extrude the sketch profile 2 inches one direction.
Step 6: Create the side angle profile sketch
Select the Front Plane & create a new sketch.
Use the sketch here as reference for creating the profile to cut the side angles of the stand.
Select the Cut-Extrude feature when you have completed the sketch.
Step 7: Cut-Extude side angle
Select Through All in the the Cut-Extrude feature to cut the side angle of your iPhone stand.
Step 8: Mirror body
Select the Mirror feature.
Mirror the body using the Right Plane.
Step 9: Add fillets
Select the Fillet feature.
Select all of the edges you want to have a radius on. Set the fillet dimension to 0.05 inches.