So you know how to design a circuit board, assemble the parts, and have a functional device at the end of a soldering session. Great, but if you want to use that device in the real world, you’re probably going to want an enclosure, and Tupperware hacked with an Exacto knife just won’t cut it. It’s actually not that hard to design a custom enclosure for you board, as [Glen] demonstrates with a custom 3D printed project box.
[Glen]’s board, a quad RS-422 transmitter with a PMOD connector, was designed in Eagle. There are a vast array of scripts and plugins for this kind of mechanical design work, including the EagleUP plugins that turn an Eagle PCB into a 3D object that can be imported into SketchUp.
Taking measurements from Eagle, [Glen] designed a small project box that fits the PCB. A few standoffs were added, and the board itself was imported into SketchUp. From there, all he needed to do was to subtract the outline of the connectors from the walls of then enclosure for a custom-fit case. Much better than Tupperware, and much easier than designing a laser cut enclosure.
Once the enclosure was complete, [Glen] exported the design as an STL, ready for 3D printing or in his case, sending off to Shapeways. Either way, the result is a custom enclosure with a perfect fit.
When building a one-off DIY project, appearances tend to be the least of our priorities. We just want to get the device working, and crammed into some project case. For those that like to build nicer looking prototypes [JumperOne] came up with a slick method of building a custom front panel for your DIY project.
The first step is to get the dimensions correct. You CAD tool will generate these from your design. [JumperOne] took these measurements into Inkscape, an open source vector graphics tool. Once it’s in Inkscape, the panel can be designed around the controls. This gets printed out and aligned on a plastic enclosure, which allows the holes to be marked and drilled.
With the electronics in place, the front panel gets printed again on a general purpose adhesive sheet. Next up is a piece of cold laminating film, which protects the label. Finally, holes are cut for the controls. Note that the display and LEDs are left covered, which allows the film to diffuse the light. The final result looks good, and can provide all the needed instructions directly on the panel.
[Thanks to Ryan for the tip]
Even network engineers who toil away in hot server rooms (which aren’t actually all that hot because they’re well climate controlled) deserve nice things. That’s why Cobalt came out with these gorgeous front bezels for their rack mounted equipment… around twenty years ago. [Geekmansworld] is reviving the look, but he’s not hiding it away in a server rack. He scrapped the guts and used the front bezel and controls as part of his media server.
His first new addition to the case was a pair of hard drives which connect to an eSATA hub also stored in the enclosure. He buttoned it up and gave it a test run. Everything worked smoothly and he hopes that it will continue that way without overheating when the summer rolls around again.
Of course a dead front bezel is no fun so he cut off the portion of the original circuit board which hosts the buttons seen on the right. These buttons now connect to a U-HID board which turns the button presses into mouse or keyboard inputs using a USB connection. The original display was swapped out for a backlit character LCD. The LEDs to the left are a refit which turns the status indicators into a VU-Meter. See the entire thing at work after the break.
Continue reading “Cobalt RaQ Retrofit Help Geek Up Your Entertainment Center”
[Michel] was in need of a 9V battery connector, and in a brilliant bit of insight realized 9V batteries will plug directly into other 9V batteries (just… don’t do that. ever.) Taking a dead 9V, he tore it open, was disappointed by the lack of AAAA cells, and soldered some wires onto the connector.
Sometimes a project starts off as a reasonable endeavour, but quickly becomes something much more awesome. [Wallyman] started off building a hammock stand and ended up making a giant slingshot. We’re not one to argue with something that just became a million times more fun.
We’ve seen solder stencils made out of laser-cut metal, photoetched metal, plastic cut on a vinyl cutter, laser-cut plastic, and now finally one made on a 3D printer. It’s a pretty simple process – get the tCream layer into a .DXF file, then subtract it from a plastic plate in OpenSCAD.
Apple loves their proprietary screws, and when [Jim] tried to open his Macbook Air with the pentalobe screwdriver that came with an iPhone repair kit, he found it was too large. No problem, then: just grind it down. Now if only someone could tell us why a laptop uses smaller screws than a phone…
[Victor] has been playing around with an RTLSDR USB TV tuner dongle for a few months now. It’s a great tool, but the USB thumb drive form factor wasn’t sitting well with him. To fix that, he stuck everything into a classy painted Hammond 1590A enclosure. It looks much cooler, and now [Victor] can waterproof his toy and add a ferrite to clean things up.
At first glance, [John’s] CD-ROM RasPi case may not seem all that unique, but we like both the implementation as well as the end-result functionality it provides. His goal was to use the Pi as a torrent downloader, and to store the downloaded files on a shared network drive. The Pi drive would slide into a bay in the server’s case—hence the Inception reference: a computer in a computer—allowing downloads while putting another step between the server and the outside world keeping, as well as guaranteeing that the network share would be available, because the server and the Pi would use the same power source.
[John] gutted the CD-ROM’s internals to leave only the PCB, which he stripped of most everything save for the power connector in the back. He then used the base of his old RasPi case as a standoff, mounting it to the top of the CD-ROM’s PCB. He soldered the power lines to the ROM’s power connector and temporarily hooked up a 5V adapter until he gets the server running. The final step was to carve out the back of the case for access to the Ethernet and USB ports, which [John] accomplished with a dremel, a hacksaw and a file. The front of the case still looks like a stock CD-ROM drive, and [John] has plans for future mods: re-purposing the LED to show network activity and modifying the buttons to serve as a reset, pause, or start for torrent downloads.
About the size of a shoebox and stuffed with a compact battery/inverter combo, the BatBox packs a mean wallop at 480Wh. What else was [Bill Porter] supposed to do with his free time? He’s already mailed out electronic wedding invitations and built custom LED centerpieces for the reception. He and his wife [Mara] then made an appearance in a Sunday roundup tying the knot by soldering a circuit together. Surely the LED Tetris Tie would have been in the ceremony had it existed. This time, though, [Bill’s] scrounged up some leftover electronics to put a realistic spin on a Minecraft favorite: the BatBox.
A pair of 18V high energy density batteries connect up to a 12V regulator, stepping them down to drive a 110VAC inverter. The BatBox also supplies 5V USB and 12VDC output for portable devices. Unfortunately, [Bill]’s first inverter turned out to be a low-quality, voltage-spiking traitor; it managed to let the smoke out of his fish tank’s LED bar by roasting the power supply. Undeterred, [Bill] pressed on with a new, higher-quality inverter that sits on an acrylic shelf above the batteries. OpenBeam aluminum extrusion seals up the remainder of the enclosure, completing the BatBox with a frame that looks both appealing and durable.
Making that final push to button up your projects can be a bit daunting. It’s kind of like the punch list on a construction project — add switch plates, fill nail holes in baseboards, screw in light bulbs, clean windows — that stuff adds up quickly. But having a set of best practices in mind throughout the development phase will cut down on that burden. [Caleb P.] just published a quick guide using a recent project as an example.
First and foremost is the label seen on the project box lid. How many times have you pulled out a circuit board from a year or two earlier and not been able to figure out the pinout? As with ancient televisions and radios, including the service schematic will save you big time! He also mentions that the size and orientation of the components in the case was in the back of his mind the whole time. That paid off because everything fits like a glove. [Caleb] makes sure the battery is easy to get to, and the each component has some type of connector so that it may be removed and serviced/replace without soldering. There’s certainly nothing groundbreaking in this guide. But ask yourself: have I been following all of these guidelines in my own work?