Old Volvo Key Fob Case Shell

The casing of my Volvo V40 (2002) key fob broke after several drops and years of wear. As usually happens, the shell starts separating and opening on its own.

The “temporary fix” was simply wrapping some tape around it to keep it closed.

Surprisingly… it wasn’t that bad. It was practical, and I’ve been using it like that for years 😅

Recently, I got a Bambu Lab P1S, and I’ve started solving small everyday “problems” like this one. It was finally time to give it a proper solution.

🔎 About the Model

It took me quite a while to find a compatible model for this specific key type, but I eventually found a base model that worked as a starting point.

I created a full remix in Blender, modifying several aspects:

✏️ Changes made compared to the original model:

• ✔️ Added bevels and rounded edges for better ergonomics and aesthetics
• ✔️ Dimensional adjustments for a much tighter fit
• ✔️ Small internal raised support for the PCB (replicating the original Volvo key design)
• ✔️ Adjusted slot to reuse the original key emblem
• ✔️ Added rear stop to allow gluing the emblem in place if desired
• ✔️ Overall improved closure and fit

The result is a case that fits very tightly and securely, completely eliminating the need for tape fixes.

🛠️ Assembly

The fit is intentionally tight to prevent any looseness.

Tip for the Volvo emblem: To easily fit the original Volvo emblem, after removing it from the original case, the easiest method is to insert it from the back while it partially engages, and once it is almost in place, press it fully into its final position.:

(If you reuse the original emblem, you can secure it with a small drop of glue thanks to the rear stop that was added.)

🖨️ Printing Recommendations

• Recommended material: ABS (more heat resistant — ideal for a key fob that may stay inside a hot car)
• Also tested in PLA, and it works very well under normal use
• Layer height: 0.16 mm
• Infill: 15%
• No supports required, even though there is a small internal overhang — it prints without issues
• Orientation: Outer face placed on the build plate

💰 Printing Cost

Printed in PLA (eSun filament), the estimated cost is:

🧾 €0.22

A very affordable way to give your key fob a second life.

If you’d rather buy a replacement case instead of printing it, here’s a cheap option (under €2, shipping may vary):

👉 https://s.click.aliexpress.com/e/_c3DIm17Z

☕ Support

This is my second personal 3D printing project, and I’m still learning Blender and Bambu Studio.

If you find this design useful and would like to support future improvements, you can buy me a coffee ☕

👉 https://buymeacoffee.com/makeralcala

Totally optional — but greatly appreciated!

✅ Final Result

A clean, functional, and much more durable solution than using tape.

Perfect for those of us who still enjoy driving this model and want to keep it working without overspending.

If you print it or improve it further, I’d love to see your version!