3D printed enclosure

99 Articles

3D Print Your Way To A Bartop Arcade Cabinet

April 22, 2020 by 3 Comments

Custom arcade machines have always been a fairly common project in the hacker and maker circles, but they’ve really taken off with the advent of the Raspberry Pi and turn-key controller kits. With all the internals neatly sorted, the only thing you need to figure out is the cabinet itself. Unfortunately, that’s often the trickiest part. Without proper woodworking tools, or ideally a CNC router, it can be tough going to build a decent looking cabinet out of the traditional MDF panels.

But if you’re willing to leave wood behind, [Gerrit Gazic] might have a solution for you. This bartop arcade, which he calls the simplyRetro D8, uses a fully 3D printed cabinet. He’s gone through the trouble of designing it so there are no visible screw holes, so it looks like the whole thing was hewn from a chunk of pure synthwave ore. He notes that this can make the assembly somewhat tricky in a few spots, but we think it’s a worthy compromise.

Given the squat profile of the simplyRetro, the internals are packed in a bit tighter than we’re accustomed to seeing in a arcade build. But there’s still more than enough room for the Raspberry Pi, eight inch touch screen HDMI panel, and all the controls. To keep things as neat as possible, [Gerrit] even added integrated zip tie mount points; a worthwhile CAD tip that’s certainly not limited to arcade cabinets.

[Gerrit] has included not only the STL files for this design, but also the Fusion 360 Archive should you want to make any modifications. There’s also a complete Bill of Materials, as well as detailed instructions on how to pull it all together. If you’ve ever wanted your own arcade machine but felt a bit overwhelmed about figuring out all the nuances on your own, the simplyRetro could be the project you’ve been waiting for.

Of course if you do have access to a CNC or laser cutter, then there are some designs you could produce quite a bit faster.

Heavyweight Cyberdeck Is In A Class Of Its Own

April 20, 2020 by 24 Comments

Inspired by other builds he’d seen online, [BlastoSupreme] decided to build his very own cyberdeck. There was only one problem: he’d never designed and assembled anything like this before. Wanting to avoid any problems down the line, he reasoned that the safest approach would be to make it so big that he wouldn’t struggle to fit everything inside. Some may say the resulting NX-Yamato, named for the most massive battleship ever constructed, ended up being too large. But that’s only because they are afraid.

A finish like the Yamato’s doesn’t come easy.

In his write-up on The Cyberdeck Cafe, a site dedicated to the community sprouting up around these futuristic personal computers, [BlastoSupreme] describes building this cyberdeck as something of a transformative experience. Looking at the incredible effort that went into this project, we can believe it. From the intricate CAD work to the absolutely phenomenal finish on the Yamato’s 3D printed frame, there’s not a cut corner in sight.

That’s right, nearly every component of this cyberdeck was conjured into existence by squirting out hot plastic. About two kilograms of it, to be precise. It was printed in vertical chunks which were then assembled with adhesive and screws. This modular construction technique allowed [BlastoSupreme] to build what he believes to be the largest cyberdeck ever made. Sounds a lot like a challenge to us.

Admittedly, the massive internal volume of the Yamato is largely unused; all that’s inside it right now is a Raspberry Pi 4 and a X705 power management board that allows the deck to run off of 18650 cells. Of course, all that space could easily be put to use with additional gear or even a larger and more powerful Single Board Computer (SBC) such as the Atomic Pi. There’s even a dedicated compartment in the side for snacks, so no worries there. As [BlastoSupreme] puts it, all that empty space inside is a feature, not a bug.

Plenty of room inside for whatever hardware you want to take with you into the Sprawl.

In the nearly two years that have passed since we first came across one of these Neuromancer inspired builds, we’ve been absolutely blown away by the increasing scale and complexity of these extremely personal computers. Since it seems there’s only a fairly loose idea of what a “proper” cyberdeck should look like in the canonical sense, these builds have been free to fill in the blanks with some pretty outlandish designs. Some of which have earned William Gibson’s personal seal of approval.

3D Printed Speakers With Many Lessons Learned

April 18, 2020 by 24 Comments

Although we all wish that our projects would turn out perfect with no hiccups, the lessons learned from a frustrating project can sometimes be more valuable than the project itself. [Thomas Sanladerer] found this to be the case while trying to build the five satellite speakers for a 5.1 surround sound system, and fortunately shared the entire process with us in all its messy glory.

[Thomas] wanted something a little more attractive than simple rectangular boxes, so he settled on a very nice curved design with few flat faces and no sharp corners, 3D printed in PLA. Inside each is an affordable broadband speaker driver and tweeter, with a crossover circuit to improve the sound quality and protect the drivers. The manufacturer of the drivers, Visatron, provides very nice speaker simulation software to select the appropriate drivers and design the crossover circuit. The front of each speaker consisted of a 3D printed frame, covered with material from a cut-up T-shirt. These covers attach to the main body using magnets and really look the part.

After printing, [Thomas] soaked all the parts in water to clean of the PVA support structures but discovered too late that the outer surfaces are not watertight and a lot of water had seeped into the parts. In an attempt to dry them he left them in the sun for a while which ended up warping some parts, so he had to reprint them anyway. The main bodies were printed in two parts and then glued together. This required a lot of sanding to smooth out the glue joints, and many cycles of paint and sanding to get rid of the layer lines. When assembling the different pieces, he found that many parts did not fit together, which he suspects was caused by incorrect calibration on the delta-bot printer he was using.

In the end, the build took almost two years, as [Thomas] needed breaks between all the frustration, and eventually only used one of the speakers. We’re glad he shared the messy parts of the project, which will hopefully spare someone else a bit of trouble in a project.

Listening to a high-quality audio setup is always a pleasure, and we’ve covered several projects from audiophiles, including affordable DML speakers, and 3D printed speaker drivers.

Continue reading “3D Printed Speakers With Many Lessons Learned” →

Using Spiral Mode To Rapidly Print Enclosures

April 13, 2020 by 24 Comments

We’ve often said that one of the best applications of desktop 3D printing is the production of custom enclosures. A bespoke case adds a touch of professionalism to any project, and considering the materials needed to print one will cost less than even the cheapest generic project box, it’s a no-brainer. There’s only one problem: it can take hours to print even a simple case.

To try and speed things up, [Electrobob] has been experimenting with running off enclosures using spiral or “vase” mode on his 3D printer. Unlike the normal layer-by-layer approach, in this mode, the printer’s hotend continually rises at a steady rate during the entire print. Think of it as akin to printing out a Slinky and you should get the idea.

Spiral printed boxes may need manual retouching

As you might expect, there are some trade-offs here. For one, the walls of the box can’t be very thick since the printer is only making one pass. The nozzle on most printers is 0.4 mm, but in his experiments, [Electrobob] has found he’s able to reliably double that to a wall thickness of 0.8 mm by adjusting the extrusion rate.

You also need to approach the design a bit differently during the CAD phase. Printing holes in the side of the enclosure, which would be easy enough to do normally, doesn’t really work when running in spiral mode. For those situations, [Electrobob] recommends designing a “pocket” into the side that you can come back and cut out with a knife. It will add a little time to the post-processing stage, but the time saved during the print will more than make up for it.

So how much faster are we talking about? In the example [Electrobob] shows in his write-up, the print time went from nearly two hours to just 18 minutes. The resulting enclosure obviously looks a bit different than the traditionally printed version, and isn’t as strong, but the concept still clearly holds promise for some applications. If you’re building a sensor network that needs a bunch of enclosures, those time savings will really add up.

This Compact Pi Terminal Will Show You The Way

March 13, 2020 by 21 Comments

The Raspberry Pi holds incredible promise for those looking to build a small mobile terminal that they can take with them on the go, something you can throw into your bag and pull out whenever there’s some hacking to be done. But getting the diminutive Linux board to that point can take quite a bit of work. You need to find a suitably small keyboard, design a custom case, and wire it all up without letting any of that pesky Magic Smoke escape.

But a recent project from [remag293] might make things a bit easier for those looking to get their feet wet in the world of custom mobile computers. The boxy handheld device has everything you need, and nothing you don’t. A basic case, a short parts list, and an absolute minimum of wiring. What’s not to love? Even if you don’t make an exact clone of this device, it’s an excellent reference to quickly bootstrap your own bespoke terminal.

So what’s inside the 3D printed case? Not a whole lot, really. Obviously there’s a Raspberry Pi, a 3.5 inch TFT touch screen display, and a miniature keyboard. The keyboard is of the Bluetooth variety, and other than being freed from its enclosure and wired into the header on the display module for power, it’s otherwise stock.

As for the parts you can’t see from the outside, there’s a 3.7 V 4400 mAh battery pack and an Adafruit PowerBoost 1000 module to handle charging and power distribution. Beyond the big lighted button on the side (which you could certainly replace with something more low-key should you chose), that’s about it. When it’s all together, you’ve got a battery powered computer that’s ready for the road with a minimum amount of fuss.

If you’re looking for something that’s a bit larger, and more than a little unconventional, you could start by printing out a full cyberdeck. After all, if you’re going to build your own non-traditional portable computer, you might as well go all out.

A Very Buttoned Up Raspberry Pi Media Server

February 7, 2020 by 21 Comments

Projects that turn the Raspberry Pi into a low-cost Network Attached Storage (NAS) solution are very common; all you need is the right software, the Pi itself, and some USB storage devices. But unless you particularly like the “Medusa” look, with loose cables running all over the place, you’ll probably want to put the hardware into a suitable enclosure. Unfortunately, that’s where the somewhat unusual layout of the Pi can make things tricky.

Which is why [AraymBox] came up with this unique “capsule” enclosure for the Raspberry Pi and two USB-attached hard drives. Every effort has been made to keep the outside of this design as clean and streamlined as possible. The asymmetrical loops of wires that we so often see on other projects are gone, with everything been brought inside thanks to some clever wiring. This enclosure looks like a professional product, and if you’re willing to put in the effort, you can have one to call your own.

The good news is that the 3D printed enclosure only has four parts, albeit rather large ones, and none of which require support material. So it should be an easy print even on a relatively low-end machine. Of course, you’re not going to get that futuristic metallic look without a little work. You’ll need to do a considerable amount of sanding, filling, and paint work to get that kind of a surface finish. Then again, that rough “just printed” look has a certain cyberpunk appeal to it as well.

But the printed enclosure is only half the battle. Inside, [AraymBox] has soldered the USB to SATA adapter cables directly to the Raspberry Pi to keep things tight and compact. A micro USB breakout board was then used to add a power connector on the back of the device where the Ethernet and USB ports are, solving the issue of having one lonely USB cable coming out of the side of the case.

In the past we’ve seen other attempts to create a 3D printable enclosure for Pi servers, with varying levels of success. While some would argue that the better solution is to just throw the Pi and the drives in a large enough enclosure that it doesn’t matter what the wiring looks like, we appreciate the effort that some hackers are willing to put in to make something custom.

Up Your Game With DIY Headset Motion Tracking

February 2, 2020 by 5 Comments

While there’s been a lot of advancements in VR gaming over the last couple of years, plenty of folks are still happy enough to just stare at their monitor. But that’s not to say some of those fancy head-tracking tricks wouldn’t be a welcome addition to their repertoire. For players who are literally looking to get their head in the game, [Adrian Schwizgebel] has created qeMotion.

The idea here is simple enough: attach a motion sensor to a standard gaming headset (here a MPU-6050 IMU), and use the data from it to virtually “press” keys through USB HID emulation. Many first person shooter games offer the ability to lean left or right by pressing Q or E respectively, so all [Adrian] had to do was map the appropriate accelerometer readings to those keys for it to work seamlessly with popular titles such as Tom Clancy’s Rainbow Six Siege and Insurgency.

The concept might be basic, but the execution is anything but. Rather than just duct taping an Arduino to his headset, [Adrian] designed a very slick 3D printed enclosure for the electronics that sits on his desk. While they haven’t all been implemented yet, the devices features indicator lights and buttons to switch through various modes. The sensor on the headset has similarly been encased in a very professional looking 3D printed box, complete with a nice braided cable to link it to the desk unit.

It’s been awhile since we’ve seen a head tracking project, and most of those utilized something like the Wii Remote. Adding sensors to a person’s head normally wouldn’t be an ideal situation, but if you’re going to be wearing the headset anyway to listen to the game and chat, it’s not really a problem. If your hair is too nice for the qeMotion, you could always try doing something similar with computer vision.

Continue reading “Up Your Game With DIY Headset Motion Tracking” →