From Prototype to Solution
Design
The design began with a 2D template informed by lessons learned from my first prototype.
My initial concept was a simple two-piece construction — a canvas back that folded over to cover the front and a clear plastic inner front—sewn together to create a friction-fit pocket.
While this proved that the clear PVC was touch-screen compatible and the webbing attachment system was secure, it had functional limitations.
Without dedicated side panels, the pouch was unnecessarily bulky and made accessing the phone's side buttons nearly impossible. To solve this, I evolved the design to include sewn-in canvas sides
Prepping the Pieces
With the design ready, I printed paper templates to easily transfer it to the materials.
While cutting out the canvas, I identified several minor improvements, leading to a more refined final version than the initial layout.
I updated the master template to reflect these alterations before moving forward
— Now Version 1 alt 2
The Build & The "Oops"
Assembling the pouch was generally successful; the seam allowances were accurate and the dimensions spot on.
However, after unpicking some initial stitching due to a thread issue, I accidentally reversed the assembly order of the back and side panels.
This created small gaps at the top where the cover folds over. While modern phone IP ratings make this a minor concern, I added material extensions to bridge the openings and keep out debris.
This fix works well and blends with the rest of the design, though it is not reflected in the master designs.
The Final Piece & Lessons Learned
Final Thoughts
Overall, I'm really happy with how this turned out.
It solves the problems I had with the first version—it's a much better size now and more practical for using my phone on the go.
Since the pouch fits the phone's shape better, it's easier to hold, and I can press the side buttons without a struggle.
One small change that made a big difference was moving the bottom Velcro.
I put it on a flap that folds back over the screen instead of just hanging down. It keeps the whole thing compact and looking a lot cleaner.
What I'd Change Next Time
I did have a few mistakes during the build. I managed to get the back piece mixed up at one point, and some of my corner stitching is definitely a bit wonky, but that's down to my sewing skills, not the design itself!
If I make a Version 2, I'd look for a better way to get the phone in and out. It's a snug fit, so it can be a bit tricky to grab. I've been using the bottom Velcro tab to help push the phone up, which works, but it might be a pain if I ever switched to a smaller phone. A side zip could be a good fix to make the whole thing a bit more user-friendly.