Enhance Your Enclosures With A Shadow Line

August 7, 2023 by Donald Papp 15 Comments

Some design techniques and concepts from the injection molding world apply very nicely to 3D printing, despite them being fundamentally different processes. [Teaching Tech] demonstrates designing shadow lines into 3D printed parts whose surfaces are intended to mate up to one another.

This is a feature mainly seen in enclosures, and you’ve definitely seen it in all kinds of off-the-shelf products. Essentially, one half of the part has a slight “underbite” of a rim, and the other half has a slight “overbite”, with a bit of a standoff between the two. When placed together, the combination helps parts self-locate to one another, as well as providing a consistent appearance around the mating surfaces.

Why is this necessary? When a plastic part is made — such as an enclosure in two halves — the resulting surfaces are never truly flat. Without post-processing, the two not-quite-flat surfaces result in an inconsistent line with a varying gap between them.

By designing in a shadow line, the two parts will not only self-locate to each other for assembly, but will appear as a much more consistent fit. There will be a clear line between the two parts, but no actual visible gaps between them. Watch the whole thing explained in the video, embedded below.

This isn’t the only time design techniques from the world of injection molding have migrated to 3D printing. Crush ribs have been adapted to the world of 3D printed parts and are a tried-and-true solution to the problem of reliably obtaining a tight fit between plastic parts and hardware inserts.

Continue reading “Enhance Your Enclosures With A Shadow Line” →

Customize These 3D Printed Cases

December 12, 2021 by Al Williams 27 Comments

Building something, of course, requires your electronics skills. But packaging it is often an exercise in mechanics. You can buy off the shelf, of course, but sometimes it is hard to find just the right enclosure. You probably have a 3D printer, too, but sometimes 3D printing an entire case can be time consuming and isn’t always completely attractive. Enter [Johannes-Bosch] and Fusion 360. These 3D printed frames assemble into boxes and are easy to customize. The panels are aluminum, although we imagine you could substitute wood, acrylic, or even a 3D printed sheet of plastic, if you wanted to.

The video below shows some examples. If your German isn’t up to snuff, ask YouTube to automatically translate the subtitles and you’ll get the idea.

Continue reading “Customize These 3D Printed Cases” →

Boxes.py Has Your Lasercut Box Needs Covered

March 10, 2021 by Elliot Williams 19 Comments

I needed something to test out a low-power laser cutter, and thought that some small cardboard boxes would fit the bill nicely, so off I went to scour the Interwebs for a quick-and-dirty finger-joint box generator. And the best of the best was to be found, drumroll please, on Hackaday.io. [Florian Festi]’s boxes.py not only has a sweet web interface, covers an absurd number of box styles, and includes kerf tests to ensure that your joints are tight, but it’s also written in easy-to-extend Python for when you have really particular needs.

But you won’t need to design anything of your own. There are already boxes with living hinges, boxes that fit 19″ racks, Eurorack skiff boxes with laser-cut mounting rails, and even a generic electronics project box with mounting ears for your PCB. Console2 has integrated clips on the rear service hatch.

You need a pentagonal prism with a round opening? What size? I guess a complete arcade-style console is technically a box. Naturally, there are also geartrains and even a robot arm design. Wait, what?

Each of the box designs is fully customizable, so it’s easy to make something like a box with customized dividers, where the different compartments are specified in a sweet text markup. [Florian]’s example box set for the game Agricola is amazing.

Underpinning the code is a LOGO-like finger-joint drawing routine. This makes it relatively easy to draw your own funny shapes, and have the hard work of thinking through the joining fingers taken care of by the computer. [Florian] seems open to taking pull requests for new box shapes, but I haven’t thought of one yet.

I can’t say enough about how cool boxes.py is, and most of the demo applications are worth a look on their own. This was an entry in the Hackaday Prize back in 2017, and it’s been growing and improving ever since. Way to go, [Florian] and Co.

3D Printering: Why Aren’t Enclosures Easier?

February 2, 2021 by Donald Papp 100 Comments

For 3D printers that aren’t already enclosed, why is easily adding a cheap and effective enclosure still not a completely solved problem? The reason is simple: unless one’s needs are very basic, enclosures are more than just boxes.

Different people need different features, printers come in different shapes and sizes, and creating something that can be both manufactured and shipped cheaply is a challenge in itself. In this article I’ll explain how those things make boxing up your printer a tougher nut to crack then may seem at first glance.

Enclosures Have Different Jobs

People have different expectations of what an enclosure’s job should be, and that determines which features are important to them and which are not. Here is a list of meaningful features for 3D printer enclosures; not everything on this list is important to everyone, but everything on this list is important to someone. Continue reading “3D Printering: Why Aren’t Enclosures Easier?” →

Simple Tips For Better 3D-Printed Enclosures

November 16, 2020 by Donald Papp 23 Comments

3D printing can be great for making enclosures, and following some simple guidelines can help the whole process go much smoother. 3D Hubs has an article on designing printed enclosures that has clear steps and tips to get enclosures coming out right the first time. 3D Hubs offers 3D printing and other services, and the article starts with a short roundup of fabrication methods but the rest is a solid set of tips applicable to anyone.

The first recommendation is to model the contents of the enclosure as a way to help ensure everything fits as it should, and try to discover problems as early as possible during the design phase, before anything gets actually printed. We’ve seen how a PCB that doesn’t take the enclosure into account risks needing a redesign, because there are some issues an enclosure just can’t fix.

The rest of their advice boils down to concrete design guidelines about wall thickness (they recommend 2 mm or more), clearances (allow a minimum of 0.5 mm between internal components and enclosure), and how to size holes for fasteners, clips, or ports. These numbers aren’t absolute minimums, but good baseline values to avoid surprises.

One final useful tip is that using a uniform wall thickness throughout the enclosure is general good practice. While this isn’t strictly necessary for successful 3D printing, it will make life easier if the enclosure ever moves to injection molding. Want to know more? Our own Bob Baddeley has an excellent primer on injection molding, and his been-there-done-that perspective is invaluable.

When Project Enclosures Go Bad: A Message From The Trenches

September 3, 2019 by Maya Posch 43 Comments

A wall-mounted, electric car charging station doesn’t sound like it’d require the most exciting or complicated enclosure. This was pretty much the assumption [Mastro Gippo] and his team started out with when they decided to turn what came back from a product designer into a real enclosure for the ‘Prism’ charging hardware they had developed. As it turned out, the enclosure proved to be the most challenging part of the project.

The first thought was to make a cheap, simple prototype enclosure for integration testing. This led them through trying out FDM 3D printed enclosures, wooden enclosures, folded (glued) plastic enclosures, aluminium extruded enclosures, Zamac alloy enclosures, and finally the plastic injection molded enclosure they had been avoiding due to the high costs.

The injection mold used to produce the Prism enclosures with.

Even if it meant taking out a loan to cover the setup costs, the results really do speak for themselves with a well-integrated design and two really happy looking partners-in-business. It does make us wonder how projects lacking this kind of financial leeway can get professional-grade enclosures without breaking the proverbial bank.

FDM 3D printing is always getting better and with a lot of post-processing you can have one enclosure that looks great, but that doesn’t scale. Outsourcing it to a professional 3D printing company like Shapeways is better, but it’s still not injection-molding quality and if the product is successful you’ll eventually invert the cost/benefit you were shooting for in the first place. Where is the middle ground on great-looking enclosures? Please let us know your experiences and thoughts in the comments.

Designing Your Project To Scale: Crossing The Chasm

June 14, 2017 by Bob Baddeley 21 Comments

Hackaday is all about the neat hacks and the repurposing of old components into new projects, but many people then try to take those projects and turn them into businesses. We’ve seen lots of people offer their stuff as kits and sell them on Tindie, with the rare few going on to develop a consumer electronic product at scale.

The Hackaday Prize 2017 Best Product highlights this journey. “Scale” itself is a vague term, but essentially it means to be able to produce enough to meet market demand. We hope that market demand is roughly 7 billion units, purchasing yearly, but the reality is that it is somewhere between 1 and a few hundred thousand, with very big differences in manufacturing at each order of magnitude. So how do you start with a proof of concept and design your product from the very beginning to be optimized to scale to meet whatever demand you can handle?

Continue reading “Designing Your Project To Scale: Crossing The Chasm” →