Bringing BACK The Lightning Port on iPhones



After turning the iPhone into USB-C before Apple did, you asked me to do the impossible: bring Lightning back. This time, I’m reverse engineering a Lightning connector into a custom iPhone 17 Pro case, built from scratch as a rapid prototype in just a few days. Follow along on this full engineering journey as I design custom PCBs for precise connector placement, 3D print a flexible case in TPU on my Formlabs SLS printer, reuse loose powder for zero waste, and use my Prusa for printing a magnet installation jig. From electronics design and board miniaturization to CAD modeling, MagSafe magnet alignment, and snap-fit assembly, this build covers the full prototyping workflow. The result? A slim, flexible TPU case that adds a working Lightning port to an Apple USB-C iPhone, with charging and all. It’s part hack, part mod, and one of the most cursed things I’ve ever built. Be careful what you wish for.

SHOP:

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Tools I use: (affiliate)
PCB Manufacturing: (5$ off your first order)
Formlabs Fuse 1+ 30W Printer:
Formlabs Fuse Blast:
Formlabs Sift Machine:
Formlabs Form 3+ Printer: (500$ off with referral code “FORM3-HILMO”)
Formlabs Wash and Cure Machines:
Flairmo Nitrogen Generator:
Low Melt Solder:
PCB Holder:
Fume extractor:
Microscope:
Camera:
Macro Lens:

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Filming and editing by Ken

Music:
Scoobadive – Very Important Pineapple (courtesy of epidemicsound.com)

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31 Comments

  1. Now make a case that has the same USB C to iphone, and an audio jack, an expandable memory slot for an sd card and a fill light on the back that powers on with a touch

  2. I like the idea but I lucked my USBC the best much faster. I can do more for my network testing but I do understand something will still do like the old connector. What was that piece of equipment you put the magnetic ring in with?

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