I wanted to make some changes to the Pi Zero case and lid by red9987 and cfunseth. I re-created the design in 123D Design and made some small changes. The first is a power logo on the lid, to indicate which of the two micro-USB ports was for power, since I could never keep them straight. I also added a hole over the LED to help see the power/activity indicator. There's also a notch on the back of each cover to help open the case later. The last change was to add a block to each cover to help hold down the board inside the case when assembled. Without the block the Pi Zero kept moving around with the weight of the mini-HDMI adapter attached to it.

I added a case top with a cut-out zero logo to help with air flow for anyone that runs an overclocked board but doesn't want the gap for the IO headers.

I would suggest printing the case bottom at 100% infill, or adjust your shells to make sure the walls are solid when printed. The dividers between the USB and HDMI port are small, so without 100% fill they could be too brittle.

I printed my case with PLA+, but it should print just as well with normal PLA or PET. ABS prints might need to be scaled up to account for slight shrinking of the parts when cooled.

Print instructions

Category: Electronics Print Settings

Printer Brand: Printrbot

Printer: Printrbot Plus

Rafts: No

Supports: No

Resolution: 0.2mm

Infill: 100%

Notes:

The top covers can be printed at 20% infill to save on filament and time. The bottom should be printed at 100% for structural strength.