So 1st step was designing the case.. This step took several hours and a lot of cleaning up. Sadly the most efficient way to boolean and merged all these crystals while keeping the geometry clean and watertight (essential in 3d printing) is by doing it by hand. Almost every other software we have tried generates bad geometry, non-manifold geometric, warps or damage the detail of the model, created millions of unnecessary polygons, etc.
The 1st case i printed i keep it to straight meth crystals.. we had it printed it on clear PLA and glow in the dark Blue PLA. Clear PLA lacked appeal but we loved the glow in the Dark blue. However, the problem with PLA was that the printer (makerbot replicador 2) used to print these cases left support material thats when removed damaged the detail of the print.
We own an ABS 3d printer (Up mini!) Our in house printer doesn't print PLA only ABS so using glow in the dark blue PLA was not an option.. However, this 3D printer makes a smart support material that doesn't damage the detail of the print. Which yield us the best looking prints in white ABS.
Both of these Printers have stuff i like and i don't like. As a matter of fact we had to return the Makerbot Replicator 2 because the amount of failed prints was just ridiculous and their customer support sucks. I don't recommend any of those printers so dont take this instructable as an endorsement.. As a matter of fact we are looking for a new 3D printer so if you recommend one please let me know.
White ABS looked ok but it was missing something.. all the crystal meth cases didn't stand out as much i liked.. I wanted this case to stand out.. So i decided to take some of the detail from my Bad Wally figurine and merge it with this case.. and voila!! Now the case stood up and look amazing.. added some color to the face using a black sharpie and wow.. exactly what i wanted.
You can buy the 3d printed case from shapeways in white, light blue, red, black and white (click here
). or you can buy the white 3D printed ABS print from our website (click here