Step 1: Build the Body
The best way to make the body is to first glue the pattern on the cardboard. Then, using an exacto knife, cut out the pattern. Score the fold lines lightly and valley fold such that the paper pattern is now on the inside and nice clean cardboard is on the exterior.
The files provided are designed for an iPhone 3GS but also work with an iPhone 4/4s with little fuss.
To Design Your Own:
- If you're a student, use Solidworks or Autodesk Inventor to turn your 3D model into a flat drawing with the sheet metal tools.
- Otherwise check out Pepakura