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To make a custom Pip-Boy enclosure, choose whether you are building a costume prop, a phone holder, or a wearable computer, then design the shell around the actual device and the wearer’s arm. Measure the screen, electronics, battery, controls, connectors, mounting points, and strap position before editing CAD. Print a small test of the screen opening and fastener holes before committing to the full enclosure.
Choose the kind of Pip-Boy you want to build
These builds share a recognizable silhouette, but their interiors are not interchangeable. Decide what the enclosure must hold before choosing a model or changing its dimensions.
| Build path | What goes inside | Fit and customization | Main tradeoff |
|---|---|---|---|
| Prop shell | No computer required; controls can be decorative | Prioritize the silhouette, arm fit, closure, and finish | Least electronics work, but it needs its own plan for weight, access, and fastening |
| Phone holder | A smartphone provides the display | Check phone width, height, thickness, buttons, camera, and how it enters the case | A phone-sized shell may not have room for a separate computer and wiring |
| Raspberry Pi 3000 | The Adafruit guide uses a Raspberry Pi Model B+, 3.5-inch PiTFT, battery, and controls | Its open CAD files include cutouts for most Pi I/O ports | A detailed functional example, but it requires more parts and integration work |
| Pip-Boy 2040 | An RP2040-based wearable build | A compact, three-part case with specified hardware and USB-C alignment | Useful as a defined small-computer example, but its parts and fasteners are model-specific |
| Custom computer enclosure | Hardware chosen by the builder | Lay out the exact board, display, battery, controls, ports, and wires in CAD | Most adaptable and the most demanding to design and test |
Prop or phone-sized shell
Ytec’s classic Pip-Boy 3000 is explicitly designed to hold a smartphone, not a ready-made Raspberry Pi computer. Its stated internal dimensions are 139 × 75 × 16 mm; check the phone’s actual dimensions and insertion path against the model rather than assuming every phone will fit. The project page lists 500 g of PLA or ABS among its materials, along with glue, screws, paint, magnets, and Velcro straps. That quantity belongs to this design, not to every Pip-Boy print. Ytec: Pip-Boy 3000
Functional computer
Adafruit’s Raspberry Pi Pipboy 3000 guide documents a build around a Raspberry Pi Model B+, a 3.5-inch PiTFT, a rechargeable 2200 mAh battery, and LED and rotary controls, among other parts. The guide says the printed enclosure has cutouts for most Pi I/O ports, making access to peripherals part of the design. Its CAD was made in Fusion 360 and is available in several formats; check the current downloadable files for their exact license and compatibility before remixing. The older guide’s dimensions and electronics should not be assumed to fit newer boards or displays. Adafruit: Raspberry Pi Pipboy 3000
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Adafruit’s separate Pip-Boy 2040 is a smaller RP2040-based case with defined print and assembly details. The Raspberry Pi Foundation’s March 24, 2020 feature on a Pi Zero W wearable describes a custom interface connected to a GPIO display and calls that project “not what we’d call a beginner’s project.” It is a useful indication of the integration involved in a functional build, but it is not an enclosure tutorial. Raspberry Pi Foundation: Pip-Boy 3000 project feature
Measure the hardware and wearer before editing CAD
For a functional enclosure, choose the electronics first. A screen opening, port cutout, battery cavity, control mount, and wire route all depend on the exact components. Measure with calipers where possible, and account for connectors and wires—not just the board outline.
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- Display: Measure the visible area and the full module, including its bezel, mounting holes, and cable connection. Plan how it will be inserted and removed.
- Board and controls: Record board dimensions, standoff positions, switch or encoder locations, and the space needed to operate them.
- Ports and wires: Locate USB, audio, power, and other connectors. Check that a plug can be inserted and that cables can bend without being pinched.
- Battery: Measure the battery and its connector, then leave a practical path for wiring and access for service.
- Arm and strap: Measure over the costume sleeve you intend to wear. Choose the strap location and closure, and allow adjustment rather than assuming one size fits every arm.
Use source CAD when available so you can change internal features without disturbing every mating surface. Ytec’s Mark IV page lists 100%, 108%, and 115% variants and warns that arbitrary scaling can make tapped screw holes too large. Its “accurate” edition is described as unfinished, so do not treat it as a completed plug-and-play computer case. The page recommends adapting source files to the components available for a wearable-computer build. Ytec: Pip-Boy 3000 Mark IV
Make and check a model-specific design
Before printing the shell, check that it can be assembled and serviced. Verify that the display can be installed, ports remain reachable, the enclosure opens as intended, and screws or inserts have room in the plastic. A small test print of the screen bezel, a standoff, or a fastener hole can expose a bad fit while it is still cheap to correct.
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- Keep the screen opening and its mounting points tied to the actual display module.
- Leave clearance for connectors, wire bends, and ordinary variation in printed dimensions.
- Check the slicer preview for unsupported overhangs and places where support material could become trapped.
- Test the arm attachment over the intended sleeve, and make sure the closure does not block controls or ports.
Do not enlarge or shrink the entire model as a shortcut when the screw holes and joints need to retain their original dimensions. If a model provides size variants, compare their internal dimensions and hardware fit before choosing one; a percentage label alone does not confirm compatibility with your electronics.
Slice and print for the selected files
Print settings are specific to the model and printer. Adafruit’s Pip-Boy 2040 guide specifies a 0.2 mm layer height and 18% infill for its case files. Those values are starting points for that design, not universal settings for every Pip-Boy or material. Adafruit: Pip-Boy 2040 case
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For its Raspberry Pi Pipboy 3000 parts, Adafruit recommends PLA to reduce warping and splitting. The guide identifies the base-main and rotary-case parts as needing support, with localized support sufficient for the base-main. Inspect the model and slicer preview for your own printer and orientation rather than applying those support instructions to unrelated files. Adafruit: Raspberry Pi Pipboy 3000 3D printing
Independent reader supportYour contribution helps us test, update, and keep practical guides available for everyone.Assemble using the hardware for that design
Fastener systems differ across Pip-Boy models. Keep each assembly procedure with the files it was written for instead of combining screw sizes into one generic list.
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Adafruit Raspberry Pi Pipboy 3000
The guide calls for tapping the printed standoffs with a #4-40 tap or machine screw, only about halfway through. Its armband and base-main parts have magnet pockets; check magnet polarity and fit before gluing. The guide lists flat pliers and flush diagonal snips for support and print cleanup. Adafruit: Raspberry Pi Pipboy 3000 3D printing
Adafruit Pip-Boy 2040
The case guide specifies four M4 × 0.7 brass heat-set inserts and M4 × 30 mm socket-head screws for the case sections, plus M2.5 × 10 mm screws and nuts for the display and board assembly. Sink the inserts carefully, align the USB-C opening, and check that the port is accessible before tightening the case. The guide supports a nylon watch strap or hook-and-loop fastening. Adafruit: Pip-Boy 2040 case
Other downloadable models
Use the hardware list and assembly guidance attached to the exact model you downloaded. Ytec’s classic design lists its own screw sizes and materials; those should not be substituted for the Adafruit fasteners without checking the geometry. Ytec’s Mark IV page includes a reader’s question about how to assemble the finished parts; its response points to the making page as the best available guidance while acknowledging it is not a complete step-by-step manual. Ytec: Pip-Boy 3000 Mark IV
Finish the shell and test it on your arm
Clean up support marks and rough edges before painting. Assemble the electronics and check the display, controls, charging or power connection, and any intended peripherals while the case is still easy to open. Then wear-test it over the actual sleeve: check for pressure points, a slipping strap, blocked movement, and a closure you can operate. The referenced guides do not establish a universal fit or safety specification, so this is a practical comfort and function check, not a certified result.
Ytec lists paint, glue, magnets, and Velcro for its classic design; Adafruit’s 2040 case permits a nylon strap or hook-and-loop fastening. These are options for those designs, not requirements for every build. Ytec states that its classic project is licensed Creative Commons Attribution-ShareAlike. Adafruit describes its CAD as open source; verify the exact license on the current downloadable files before redistributing a remix.
Quick Recap
Plan the build around its real constraints
- Electronics determine the enclosure: A phone shell may need substantial redesign to fit a board, separate display, battery, and wiring.
- Published settings are model-specific: Use the cited print settings only with their corresponding files, then assess the printer, material, orientation, and required strength.
- Scaling changes mechanical fit: Preserve screw-hole and joint dimensions or redesign them deliberately; overall percentages do not guarantee a usable fit.
- Assembly hardware is not interchangeable: The Pi 3000’s #4-40 tapping and magnet pockets differ from the 2040’s M4 inserts and M2.5 display hardware.
- Compatibility is not implied by the name: The documented Pi 3000 build uses older Pi B+ and PiTFT hardware; measure your exact components against the files.
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