enclosure

89 Articles

Building Better Cases With A Laser Cutter

June 26, 2012 by 16 Comments

[Ryan] just got his Raspberry Pi, and what better way to add a new toy to your workbench than by building a case for it? Using a laser cutter and 3D printer, [Ryan] managed to make a case that is sure to be the envy of all the other tinkerers at his hackerspace.

The build started off with a piece of dark red acrylic in a laser cutter. After cutting the Raspberry Pi logo out of this acrylic, [Ryan] cut the same logo – a little bit larger – out of plywood. Because he was very careful to measure the kerf (or the width of the laser beam/saw blade/what have you), the wooded version of the Raspi logo fit snugly inside the acrylic cut out.

The sides of the enclosure are a single piece of plywood with a kerf bend, making for a very attractive rounded case. Finally, the Raspberry Pi is mounted on a Pi plate printed on a Ultimaker.

For as many builds we see using a laser cutter here on Hackaday, there’s surprisingly little information on exploiting the true potential of these machines with marquetry, intarsia, or fretwork. Enclosures are always cool, so if you have a very elegant laser cut box, send it in and we’ll put it up.

Make Your Next Enclosure Out Of Stone

June 6, 2012 by 17 Comments

Sure, a laser-cut plywood enclosure adds a lot of maker cred, and custom plastic or cast aluminum enclosure belies an engineering and design prowess. [ardiyno] didn’t want one of these run-of-the-mill enclosures, so he made one from scratch out of limestone.

The stone [ardiyno] used comes from the southern bit of his native Netherlands. It’s a very nice limestone, easily carvable and capable of very fine detail as seen in [ardiyno]’s scary/creepy carved limestone bookends.

Inside the enclosure, [ardiyno] has a calendar/clock/environmental sensor displaying the current date, time, relative humidity, and light level on twelve 14-segment displays. [ardiyno] admits the enclosure is a bit oversized for how much space his project takes up, but the extra space is meant for future internal expansions.

After the break, you can check out [ardiyno]’s method of using a screw driver to carve the limestone. Normally, we’d call foul over someone abusing tools, but the limestone is so soft (the pyramids were made out of limestone using soft copper tools), there’s most likely very little damage to the screwdriver.

via reddit

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8-bit Computer Project Lands In A Philco Radio Case

March 5, 2012 by 17 Comments

We’ve enjoyed seeing the development progress of Veronica, [Quinn Dunki’s] 8-bit computer project. It started out on a breadboard, then moved to edge-connected PCBs, and now [Quinn] has given Veronica a body of her own.

The donor is a Philco Model 42-327T and was produced in 1942. It was chosen because it is non-functional and missing several pieces. We wonder about the collector’s value of the piece but since [Quinn] snagged it from eBay there can’t be in huge demand right now. The teardown images are priceless. There seems to be no reasoning behind component placement for the beast. It looks more like a junk drawer packed full of relic components than something that actually worked once upon a time.

But we digress. After gutting the retro wooden case [Quinn] set out to fabricate her own face plate. Since she’s comfortable working with copper clad, she whipped up a negative design and etched the dashboard seen above. It mounts in the original dial opening, and hosts all of the controls she needs to work with the 8-bit computer. Just below is where the present buttons used to be located. You can just see the hexout display for reading data from the registers mounted in that void.

Laser Cutting Technique Makes Plywood Bendable

December 7, 2011 by 42 Comments

Here’s a laser cutting technique that makes thin plywood bendable. By cutting away elongated diamond shapes from the material, a lattice of strips connected minimally by alternating tabs is left over. The wood is then bendable, and it must be somewhat durable since the idea came from a product that uses the technique as a hinged notebook enclosure.

We don’t have much interest in it as an often used pivot point as surely it must be a problem with long-term use. But we love the look of it as a rounded corner on an enclosure like the Arduino project box seen above. The side walls are one continuous piece, with identical top and bottom sections which receive the alignment tabs. The whole thing is held together with just four bolt/washer/nut combinations.

But if you don’t have access to a laser cutter, we guess you’ll have to stick to altering pre-made enclosures for now.

Aluminum Bending Tutorial And A DIY Brake

December 7, 2011 by 10 Comments

What makes a project really exceptional? Part of it is a, ‘gee, that’s clever’ angle with a little bit of, ‘that’s actually possible.’ One thing the Hack a Day crew really appreciates is awesome enclosures. Altoids tins will get you far, but to step up to the big leagues you’ve got to bend some aluminum. Luckily, [Rupert] sent in a great tutorial on bending aluminum sheets for enclosures.

To make his press brake, [Rupert] scavenged a few pieces of 38mm bamboo worktop scraps. After assembling a few of these pieces with some hinges, he was ready to bend some aluminum.

One trick [Rupert] picked up is scoring the sheet metal on the inside of a future bend. For [Rupert]’s project, he sent his 3mm aluminum sheet through a table saw set to cut 1mm deep. Of course this should only be done with a blade designed for non-ferrous metals with as many carbide teeth as possible. Judging from [Rupert]’s homebuilt Hi-Fi that used this construction technique, the results are phenomenal.

Exterior-grade Electrical Box As Project Enclosure

December 6, 2011 by 14 Comments

The quest for a project box is always a balance between cost, complexity, and style. We think [Pcmofo] really finds the mark with his exterior electrical box enclosures. He took the time to document his fabrication process for those that want to replicate his look.

These grey plastic boxes are meant to keep the elements away from home and commercial electrical systems. They’re easy to find and come in many different sizes (this one is 8″ square and 4″ deep). The plastic is very rigid, but still easy enough to work with simple tools.

[Pcmofo] starts by eyeballing the placement of his components. Once he has a good idea of where each should be located he grabs a caliper and uses Adobe Illustrator or Inkscape to design a template. This is attached with painter’s tape, and rough openings are made using a drill press. The holes are brought to the final size by hand using files for a nice finished edge. When it comes time to mount hardware, the plastic is strong enough to hold threads if you are careful when using the tap to cut them.

The example enclosure houses a temperature controller for fermenting beer. You can see some video of the enclosure embedded after the break.

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EagleUp Pulls Your PCBs Into SketchUp

November 16, 2011 by 23 Comments

[Karl] wrote in to tell us about a software package called EagleUp that will import your Eagle CAD PCB designs into Google SketchUp. It bridges the gap between the two using the open source image processing software ImageMagick.

As you can see above, you’ll end up with a beautifully rendered 3D model of your hardware. This is a wonderful way to make sure that your enclosure designs are going to work without needing to wait for the PCBs to arrive from the fab house. It is available for Windows, OSX and Linux (although the last time we tried to run Sketchup under Wine nothing good came of it — perhaps it’s time to try again).

In [Karl’s] case, he’s working on an Arduino compatible board based around the Xmega. He mentions that EagleUp is a great way to get an idea of how component placement will end up, and to see if the silk screen layer is going to turn out well or not. Here’s a link to one of his test designs.