Tablet Device Protective Case From Binder Cover

How to transform a clear holder cover into a Tablet Device Protective Case? This is a self-made, super slim and durable sample.



I brought a tablet PC Unifox M10 a year ago. A rather rare model supports dual OSes, windows and Android, allowing user to select when start up.



The package comes with a soft pouch bag and a plastic stand. But still the device may be damaged as it got no protection when in use. Also the stand is not so convenient to bring around.



Unfortunately I cannot find a suitable case or cover from market. Therefore I planned to make one and finished months ago.

Very simple tools:

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  Cutting mat
  
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  Cutter
  
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  Steel ruler 
  
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  Pincers
  
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  Hammer
  
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  Contact adhesive
  
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  Tweezers
  
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  Adhesive tapes
  
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  Blu-tack (for fixing positions temporarily)
  
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  Pencil
  

Materials

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  Plastic sheets from the cover of 2 scrap clear holders(1mm thickness preferred)
  
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  Studs
  
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  Sponge sheets
  

Correct and accurate measurement of the device is 200% important or the device cannot fits in the case!



To measure accurately, mind the following points:

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  The edges of device may not be in straight lines. Sometime, it looks straight, still need to confirm by measurement. 
  
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  Thickness on edge may not be the same in the centre. It's better measure by caliper. But actually I don't got one. :D
  
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  Any protruded parts
  
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  Position of screen area, buttons, LED indicators, cam, sockets where holes are to be opened for access.
  

Planning and design is crucial. At the stage of design, mind the following points:

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  Thickness of the plastic sheet.
  
  As the case is in a box shape, tabs are needed on every other edge for gluing them together. Thickness of the plastic sheet should be well planned and considered in the design.
  
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  Thickness of sponge sheet
  
  Sponge sheet is placed inside the case as cushions to protect the device. It is catered at the design stage.
  
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  How the device is put in/out of the case
  

The design idea is simple -- a case accommodate the device and an separate sheet of cover attached at the back, facilitates as the support when slipped beneath the body.



It looks a bit different from the sketch. The curve surface is changed to keep it stay compact.



I made a mockup with card board to make sure the design is OK. Unfortunately, it has been thrown away and I took no picture of it.

Get start with the implementation!



There are several kinds of binder available on market which has different number of holes. The binding unit may be different. But all fastened to the cover using studs. Again, it only varies in the number of studs used.



Remove the studs and separate the binding unit from the cover using pincers, getting the remaining plastic sheet for further use.

Just treat it as cardboard!

Draw the line precisely and cut it into desire shape. Only difference from paper is the plastic sheet surface is too smooth for the  metal ruler to stay. It slides around all the time. Place blu-tack between ruler and plastic sheet to fix the position before cutting with blade.

The easiest way to make a hole is by drilling. I don't got a drill at home. Therefore making use of the stud. Fix the position of stud by blu-tack and hammer gently. circular hole is then cut out from the plastic sheet and it fits perfectly with the stud!.

When finished cutting parts, shaped to desire look, put it all together and fix the position with adhesive tape first. Sponge sheets are placed inside. See if everything fits or need further finetune. 

The outer cover is again simple in structure, just a plastic sheet wrapping up the body, linked with 4 studs at the back.

When everything are fine. Glue them all up.



Contact adhesive is a good choice. It gives strong strength to hold up the parts. On the other hand, it can be teared apart easily without any tools. Easy for fixing errors or replacing any broken parts.



Just apply the glue on both sides that need to be put together. Wait until the glue is dried completely. Test it by finger, make sure it is no longer sticky. Then put the parts together at the right position. It will be fastened at once.

The case is easy to use.







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The total thickness is 22mm while the original device is 14.5mm because I put sponge sheet on the front and back.

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Ventilation is good and the heat from metal back panel is not burning my hand any more.

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The cover is durable and I no longer worry about scratches.

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The cover works fine as a stand with adjustable angles in modes of Desktop screen input, Desktop keyboard input, and straight standing

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All buttons and sockets are accessed directly without removing the case.