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.
Step 10: Personalize with your name & save file
If you want, you can cut your name into the front of the stand by selecting the Front Plane, creating a sketch & typing your name with the Text tool.
Select Extrude-Cut & cut the letters 0.05 inches into the front.
You now can save your file as a SolidWorks Part file & an STL file to send to the MakerBot.
Step 11: Open & position in MakerBot software
Open the STL file in the MakerBot software (ReplicatorG or MakerWare).
Position the model so that it is sitting on the ground plane & in the center.
Step 12: Generate the GCode & print
Generate the GCode to create the tool path for the MakerBot.
Select the print button after the GCode has finished generating.
Step 13: Print on MakerBot
Sit back & watch your part being printed on the MakerBot. This print was set on 50% fill & took about 2 hours to complete.
The MakerBot lays down a "raft" of support material in which you will want to carefully break off & discard once it has completed printing.
Step 14: Use your new iPhone stand
Your fresh off the MakerBot stand is now complete. You can use it to display your iPhone in portrait or landscape mode.
Happy iPhone standing!