jenswilly.dk


Creating custom enclosures

29. December 2011 21:04 by Jens Willy Johannsen
Categories: PCB

For another project (that I have shamefully neglected to write about) I decided I needed to put it into some kind of enclosure. And I since I couldn't find any off-the-shelf enclosures that fit I decided to make my own.
A little bit of googling let me to Shapeways that lets you create 3D printed models from your own 3D files in several different materials.

The models themselves can be created in pretty much any 3D modeling application (including the free SketchUp or Blender). I used Luxology's modo.
Obviously, exact dimensions are important. So I got PCB dimensions and coordinates from Eagle and used a caliper to measure the size of the battery and plugs and so on. And I created dummy objects for the battery and the PCB to make sure that everything fit. This is what I came up with:

Enclosure (click for larger version)

The stand-offs have 4.1 mm holes for threaded inserts to use with M3 machine screws (like these ones from RS).

And here with the dummy objects visible:

With dummy objects (click for larger version)

I exported the object to Wavefront OBJ format and uploaded it to Shapeways (I needed to rotate 90 degrees about the X-axis first in order for the preview image to render correctly on Shapeways) and specified the units as meters (since that's what modo uses by default).

The price came to €20.14 plus shipping (€8.38 for UPS shipping) for "white, strong, flexible" material. So now it's just wait and see how it turns out.

Bear in mind, that this is my first attempt at making a 3D printed object. I haven't even smoothed the edges or added support ribs or anything. Not to mention that I have only made the bottom part of the enclosure (it does however have a "lip" for mating with the top half).

For a much nicer custom enclosure, take a look at this one (also on Shapeways).

 

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