3D printed enclosure

98 Articles

Gorgeous Omnidirectional 3D Printed Speaker

September 12, 2018 by 12 Comments

With all due respect to the hackers and makers out there that provide us with all these awesome projects to salivate over, a good deal of them tend to prioritize functionality over aesthetics. Which isn’t a bad thing necessarily, and arguably better than the alternative. But for many people there’s a certain connotation around DIY, an impression that the final product is often a little rough around the edges. It’s usually cheaper, maybe even objectively better, but rarely more attractive.

Which makes builds like this absolutely beautiful 3D printed Bluetooth speaker by [Ahmsville] especially impressive. Not only did he engineer a fantastic sounding speaker that projects stereo sound no matter where you are in the room, he clearly gave a lot of thought into making the final product look as good as it sounds.

The 3D-printed enclosure provides separation for the four internal speakers and two passive radiators, as well as holding the electronics. A custom made 3S battery powers the Bluetooth module though an isolated step-down module, and the twin 18 W TDA2030 amplifiers feed their respective pair of drivers.

The device is surrounded by an impressively detailed 3D-printed mesh, which is then wrapped with some speaker grill fabric to give it a very professional look. In the video after the break, [Ahmsville] shows a time-lapse of building the speaker, as well as a demonstration of how it sounds on his desk.

If you’re more about function than what the finished product looks like, we’ve covered speaker enclosures made out of various types of actual trash which you can take a look at.

Continue reading “Gorgeous Omnidirectional 3D Printed Speaker” →

Cheap FPV Goggles Turned Pocket Sized Display

September 8, 2018 by 10 Comments

Thanks to the exploding popularity of First Person View (FPV) RC flying over the last couple of years, the cost of the associated hardware has dropped rapidly. Today you can get entry-level FPV goggles for under $40 USD on various import sites. For the money you’re getting a 5.8 GHz receiver, battery, and an LCD display; even if the components themselves aren’t exactly high end, at that price it’s essentially an impulse buy.

[nomand] didn’t necessarily have a use for a cheap FPV headset, but he did like the idea of having a pocket sized display that he could pass off to others so they could see what he’s seeing during flights. So he harvested the principle components from a Eachine VR006 headset and designed a new 3D printed enclosure for them. The final result looks fantastic, and is much cheaper than commercial alternatives on the market.

He’s created an exceptionally detailed step-by-step guide on how you can perform the conversion yourself in the project’s GitHub repository, and has also put together a video where he goes over the modification and discusses the end result. [nomand] clearly intends for this to be a project for others to duplicate instead of a one-off build, and given the price and final results, we wouldn’t be surprised if this conversion becomes popular in FPV circles.

Perhaps the best part of this project is that it requires almost no modification of the original hardware; just soldering two wires because the original connector is too large. Otherwise just need to take the headset apart carefully, and transplant the components into the 3D-printed case [nomand] has meticulously designed. The case is so well designed it doesn’t even need any fasteners, it slides together and everything is held in with some strategically placed pieces of foam.

Between this modification and the custom built spectator display we covered recently, it looks like there’s a clear demand for sub-$50 portable FPV monitors. Seems odd that no manufacture is trying to fill this niche so far.

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Pocket-size Pi Zero Desktop Features E-paper Display

June 4, 2018 by 28 Comments

[Ramin Assadollahi] uses his Raspberry Pi Zero W as a self-contained mobile desktop, connecting to it over VNC from another computer when he wants to hack away at some code or work on a new project. But he often found himself wishing there was some convenient way of displaying pertinent into right on the device, such as what IP address the Pi Zero had pulled. Then he found the 2.13 inch e-Paper HAT for the Pi Zero from Waveshare, and it all clicked into place.

The final device, which he refers to as the StickPi, combines a Pi Zero W, the Waveshare e-Paper display, and a strip of protoboard featuring a few tactile buttons, all inside of a 3D printed case. To really get the most out of the internal volume of his case, [Ramin] soldered the header pins to the Pi Zero in the middle, allowing him to create a space-saving “sandwich” out of all the components.

With the e-Paper display, [Ramin] now has a way to show information on the device itself without having to connect to it over the network. But thanks to the tactile switches on the back connected to the Pi’s GPIO, he also has six programmable buttons that could do anything he wants.

In the most basic implementation, each button could execute a command or script on the Pi. But [Ramin] has something a little more advanced in mind. In the video after the break, he explains that his next step is going to be working on an actual user interface for the Pi’s e-Paper screen, making use of the roughly gamepad style layout of the rear buttons. A “paged” interface with scrolling options would allow the user to perform all sorts of functions quickly and easily, and we’re looking forward to seeing what he comes up with.

This isn’t the first time we’ve seen somebody try to turn the Pi Zero into a more mobile-friendly platform, and the construction method here actually reminds us of a much smaller version of the Zero Phone.

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Building The Perfect Home Router

April 12, 2018 by 43 Comments

When a favorite piece of hardware dies, it’s fairly common to experience a bit of dread. The thought that now you’ll have to go through the process of getting a replacement for the device can be very troubling, and is fraught with difficult questions. Is the hardware still available? Has it been made obsolete by something else in the time you’ve had it? But while it can be a hassle, there’s no question you can come out the other side better than you went in. Sometimes it takes the passing of an old piece of gear for you to really embrace what’s possible with the latest and greatest.

That’s exactly what happened to [Tyler Langlois]. When his trusty home router finally gave up the ghost, he was left with a couple of options. He could get another consumer router, upgrade to a enterprise-level model, or take the road less traveled and build his own router to his exacting specifications. Since you’re reading about it on Hackday, we’ll give you one guess as to which door he went through.

The blog post [Tyler] has written up about the saga of building his own router is an incredible resource for anyone who might be thinking of taking the plunge into DIY networking. From selecting the proper hardware to the nuances of getting all of the software packages installed, this is an absolute treasure trove. At the beginning of the post he mentions that the post shouldn’t be considered a comprehensive guide, but considering we’ve seen commercial hardware that wasn’t documented this well, we’d have to respectfully disagree on that point.

Some elements of his homespun may come as something of a surprise. For one, [Tyler] bucked the hive mentality and determined the Raspberry Pi simply wasn’t up to the task due (at least in part) to the single 100 Mbps network interface. He ended up going with an ESPRESSObin, a relatively niche Linux SBC that features an onboard gigabit switch in addition to a fairly hefty spec sheet. He also decided to forgo WiFi entirely, and leave the intricacies of wireless networking to a standalone access point from Ubiquity.

A router is often overlooked as just another piece of consumer kit sitting around the house, but it’s actually an excellent place to flex your creative and technical muscle. From adding a remote display to converting it into a mobile battle tank, there’s a lot more you can do with your router than stare at the blinkenlights.

A Detailed Guide For 3D Printing Enclosures

August 21, 2017 by 39 Comments

We’ve all have projects that are done, but not complete. They work, but they’re just a few PCBs wired together precariously on our desks. But fear not! A true maker’s blog has gifted us with a detailed step-by-step guide on how to make a project enclosure.

Having purchased an MP Select Mini 3D Printer, there was little to do but find something practical to print. What better than an enclosure for a recently finished Time/Date/Temperature display Arduino based device?

The enclosure in this guide, while quite nice, isn’t the main attraction here. The real feature is the incredibly detailed instructions for how to design, model and print an enclosure for any project. For the veterans out there, it seems simple. Sketch something on the back of a napkin and take a nap on your keyboard with OpenSCAD open. When you wake, BAM: perfect 3D model. However, for newcomers, the process can seem daunting. With incredibly specific instructions (an example is “Open up a new workspace by clicking CREATE NEW DESIGN,” notice the accurate capitalization!), it should ease the barrier of the first enclosure, turning the inexperienced into the kind-of-experienced.

If you’ve been printing enclosures since the dawn of time or plastic simply isn’t your style, boy, do we have you covered. Why not check out FR4 (aka PCB) enclosures? Or what about laser cut enclosures from eagle files? Maybe two-piece boxes are more your thing.

Practical Enclosure Design, Optimized For 3D Printing

May 24, 2017 by 36 Comments

[3D Hubs] have shared a handy guide on designing practical and 3D printing-friendly enclosures. The guide walks through the design of a two shell, two button remote control enclosure. It allows for a PCB mounted inside, exposes a USB port, and is optimized for 3D printing without painting itself into a corner in the process. [3D Hubs] uses Fusion 360 (free to hobbyists and startups) in their examples, but the design principles are easily implemented with any tool.

One of the tips is to design parts with wall thicknesses that are a multiple of the printer’s nozzle diameter. For example, a 2.4 mm wall thickness may sound a bit arbitrary at first, but it divides easily by the typical FDM nozzle diameter of 0.4 mm which makes slicing results more consistent and reliable. Most of us have at some point encountered a model where the slicer can’t quite decide how to handle a thin feature, delivering either a void between perimeters or an awkward attempt at infill, and this practice helps reduce that. Another tip is to minimize the number of sharp edges in the design, because rounded corners print more efficiently and with smoother motions from the print head.

The road to enclosures has many paths, including enclosures made from FR4 (aka PCB material) all the way down to scrap wood with toner transfer labeling, and certainly desktop 3D printing has been a boon to anyone who’s had to joylessly drill and saw away at a featureless plastic box.

Designing And Printing A Custom Enclosure

June 5, 2014 by 19 Comments

enclosure

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.