Waterproof iPod Shuffle 4G Case

UPDATE April 29 2019: I've overhauled the design to make it more waterproof - I've had a couple of small leaks in the old one. And, now the iPod is face-up in the case. The downside is, you'll have to put the iPod in, then insert the headphone jack adapter, and glue the adapter in place. Your iPod shuffle will be permanently encased in this thing.

UPDATE: I removed the bracket, and just made this two parts. It's stronger, easier to build and has a lower profile that way, though you will need supports for it.

I love swimming, and I hate boredom. But with music, a boring workout becomes an exhilarating race to the finish. I used to have a waterproof case for my fourth-gen iPod Shuffle, but it broke. So, I made one, and you can too. It's not fancy - you can't adjust the music once you've closed the case - but it works. I've tested it, and it's waterproof, but I can't promise that yours will work out as well, so use this at your own risk.

You'll need the following extra parts, which you can find on Amazon or elsewhere:

• 55mm x 50mm x 2mm O-ring
• FosPower 3.5mm male to female headphone jack adapter
• Glue, prefereably Loctite GO2 - it makes a great water-resistant, rubbery seal

You'll also need waterproof earbuds, they can be found on Amazon for $10 - $20.

To assemble the case, first print the bottom and the lid at 0.1mm resolution with 100% fill. Make sure to print the bottom with supports touching the build plate only, and no supports for the lid.

Next, apply some glue to the outer barrel of the headphone jack and insert it into the housing in the side of the case bottom. Be sure to push it in all the way, and give it a couple of turns so the glue gets completely distributed. It's also best if you make a little collar of glue around the junction between the case and the headphone jack to provide some extra waterproofing.

Add the O-ring onto the case bottom, it will fit into a groove at the bottom of the threaded section. Plug your iPod Shuffle into the male plug inside the case - it'll take a bit of finesse, but it will angle in.

When it's time to swim, start your playlist, fold down the iPod so it lies face down in the case (it rotates around the plug), screw the lid on tightly, and conquer those laps.

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