A cover generator for the CARD10 badge!

Features

interactive web interface available at https://card10-cover.0x1b.de/index.php (thx to segal!)
more variations possible than you'll ever need!!!
buttons become much more usable as they get a bigger surface
the cover can be clipped onto the badge - there are no tools required to change the cover
you can add a piece of clear plastic (e.g. cutout from a cheese packaging) as display protection
the model has no overhangs, thus it is very easy to print (except if you turn side led's on)
you can turn off the randomization and generate exactly the cover that YOU want!

How to use

open this code in openSCAD (download from https://www.openscad.org/)
specify whether you want a model with wristband or without (line 82) / the option with wristband also adds the wristband mounts (32 mm) to the watch cover
if you want to print a wristband, specify the sircumference of your wrist in line 107
specify from line 69 on which parts you want to generate
select in line 68 if you want to have the parts oriented ready for print or in the way they will be assembled later
[optional]: adjust settings below in the section 'CUSTOMIZE YOUR COVER BY ADJUSTING VALUES BELOW:'
hit the render button in openSCAD (the button above the code with the hourglass & the cube)
hit the .stl export button right next to the render button
print your .stl model!

Printing instructions

print upside down without support out of PLA
recommended slicer settings: 0.2mm layer height 0.4mm wall thickness / 1 wall 100% infill 0.4mm extruder

Assembly instructions

clean up the print with a small utility knife
[optional]: cut a 14mm x 30mm piece of clear plastic as display protection (e.g. from a pet-bottle) and place it inside the display cutout
If you printed a wristband: Glue FClip on the end of the bottom wristband (e.g. with superglue)
connect MClip with the top wristband (with a paper clip as axle)
connect both wristbands to the cover (with paper clips as axles)
if you printed a bottom: Unscrew the four screws on the bottom of the Card10, remove the stainless steel electrodes, add the bottom piece, add the electrodes, add the screws again.
clip the cover onto your card10 badge
print another cover for your friends

Wristband assembly

Step 1: Clean up the inside of FClip with a small file.

Step 2: Make sure that MClip fits smooth into FClip.

Step 3: Glue FClip onto the bottom piece of the wristband.

Pro-tip: Clothespins are nice for clamping the pieces together while the glue cures. A piece of tape (e.g. electric tape or the yellow back-foil on double sided tesa tape prevents the superglue to bond with the clothespins).

Step 4: Connect MClip and the top part of the wristband with a paperclip. Cut the paperclip to size.

Step 5: Heat up a piece of pipe with a hot air gun...

... and use the hot pipe to bend the wristband pieces.

Step 6: Connect the wristband pieces and the cover with paperclips.

This is the finished clip-on cover! You can also add the bottom plate to your Card10. This would be screwed in between the lower circuit board and the metal electrodes.

Examples

I added some stl files which were generated with Version 1 & 2 as examples. Here's a print of the model 1337haxx0r with all features unlocked:

All of the models feature a recessed display cutout where you can place a 30mm x 14mm transparent plastic piece as display protection.

Here's the model 'functional style' with half diffusor after losing a round of Tetris:

And here's a bunch of prints with different features. I cut out pieces from some food packaging for the screen protectors:

Thhere were plenty of test prints involved in making this work out nicely: