Flip Phone Repair

The Story:

My wife still uses a flip phone, and one day she noticed that the outside screen wasn't working anymore. Apparently there was a small plastic piece that would push a small button when the phone closed, signaling to the outside screen to turn on. However, the small plastic piece broke off, leaving nothing to push the button when the phone closed.

I decided to attempt a repair with 3D printing. Printing the small plastic button would be too small of a print to be able to handle and glue properly. I figured it would be best to design the new plastic button on a small square so that there would be more surface area to glue. My initial square broke off, leading me to attempt a new square with filleted edges, so that the circle/button would be along the edge of the backing. This lasted a little longer, but it broke off again. I suspected that when the phone opened and closed it hit against part of the square, eventually cracking it off. That's when I had the idea of shrinking the backing a little more, leaving a tiny rectangle. This finally seems to be the solution, as it has lasted a few months so far.

Below is a picture of the 3D printed piece glued onto the phone (in pink), along with a render of the 3 versions I mentioned above.