4 Steps how to make phone case

  1. Design
  2. Print
  3. Sublimate
  4. Pack

1 - Designing

The first thing we need to take care of is the design, sometimes we customize a phone case accordingly to the customer specifications but most of the time we like to provide some options and that’s where we sell them on Etsy. So we created some mockups that we can use to show our products:

designing in illustrator

We created a standard format for design to be used internally, all of our designs are placed as vectors on the illustrator and from there we can print it to continue the process. Here is a picture showing what it looks like:

design in illustrator

As you can see we already have the art in the format to be printed (in this case for LG G3 phone). This template for each cellphone model is also made by us. We use the scanner to scan the insert with the right shape, then we work with this image in illustrator to make sure that our printing will have the exactly same format of the case.


2 - Printing

Before printing the design there are a few other things that we had to take care of, for example the printer settings. As we are dealing with a different print options, we had to customize our printings settings to find the best result at the end. It also took us a few weeks to make it right.

With everything prepared we finally print our design. The printer and paper used to do that is not a normal one, we had to import both of them from Brazil.

printer and ink

We also had to modify the printer a little bit, since we are using different ink we may have a few problems to clean it, so we installed a small collector that can be seen in the picture below:

ink collector

3 - Sublimation

Once the arts are printed, we need to transfer the art to the phone cases. The Sublimation Heat Press takes part in this phase:

heat press

In this equipment we can set up the pressure and temperature that we want to use. The sublimation Heat Press had a big influence in our learning curve because we had to waste several cases to set up the right temperature and pressure

So, to transfer the art to the case we use a thermal tape that holds the case in the right position avoiding that once we start to sublime, the art stays in the right position. You can see in the following picture the plate that is going to have the art printed with the thermal tapes on the sides.

thermal tape

Before starting the sublimation process, we place a kraft paper on the machine because of the high temperature. Now that we have the insert and sublimation machine ready, we place it in the Sublimation Heat Press, set the temperature, pressure and time. We start the machine and after we get our insert printed:

insert heat pressed

Once the insert is ready, we start to prepare to attach it on the blank phone case depending on the model that was ordered.

The seal is removed from the blank phone case, and the insert is attached to the phone case, all becoming one single piece.

glue the insert

4 - Packages

Once the phone cases are made, we can start the process to make the boxes. The boxes were all designed by Geekfun using tools suchs as: Illustrator and Photoshop.

box design 

We print all the designs using another ink printer. This is our second printer only used for making boxes, thank you cards, business cards, and stickers.

After we print the boxes, we start folding and glueing the parts needed. We make different color boxes because we believe our customer likes to always receive something different and have a new experience.

final box 

In addition, we want to enhance our customer's experience and show that we really care about them. So we created stickers and thank you cards to put inside the boxes with the phone cases.


Equipments you need:

Basic Equipments for phone cases:

  • Sublimation Printer 1
  • Sublimation Heat Press
  • Blank phone cases
  • Inserts 

Basic equipments for boxes, cards, stickers:

  • Ink Printer 2
  • Thick colored papers
  • Scissors
  • Corner Scissors
  • Glue