Nintendo DS Unhinged Shell

This is a shell replacement for the launch model Nintendo DS (NTR-001 aka DS Phat) that also removes the hinges. This is a hingeless design. The top screen will not fold down.

The original DS console is known to have plastics that have not aged well, causing the shell to become fragile and commonly cracking/breaking where the hinges are. Sometimes the hinges get lost too. It's common to find lots of DSes on eBay that are already broken for cheap.

I designed this with FDM printability in mind at 0.2mm layer height and 0.4mm nozzle diameter. Parts “a” and “b” are meant to be glued/epoxied together. This is to avoid ugly surfaces on the inside/outside from support material and to reduce the supports needed to a bare minimum. I tried my absolute best for these to use as little support as possible. Be extra sure to align all the button holes and edges when gluing these two together.

PARTS B AND X REQUIRE SUPPORTS.

The top screen attaches to the bottom of the shell with two M2 sc