Custom Electronic Enclosures

Often when you build a cheap electronic kit they don't come with a box, if you have access to a 3d printer, and a laser cutter here is a simple way to make a custom enclosure that looks cool and fits right.

In this example Ill show you how to make a laser cut and 3D printed Enclosure for the 4 bits clock kit as featured in the bomb proof clock instructable , but you could adapted it to almost any size PCB or electronic kit.

This project came about as I had a few students who like the clock but are a bit scared of the welder...

As well a 3D printer and laser cutter you will need a CAD program. I use Prodesktop it's old but good.

Learning Intentions

• To work safely in the workshop
• To improve my understanding of how the CAD software works
• To operate a laser cutter and 3D printer
• To be a self-directed learner

Success Criteria

• I understand the safety rules and I am working safely in the workshop.
• I can follow the instructions independently.
• I can produce 2D and 3D CAD drawings and convert them to DXF and STL files.
• I can produce an assembly drawing.
• I can produce a photo album drawing of my project.
• I can operate a laser cutter and 3D printer.
• I can work safely and work safely in the workshop.

Before you start it can be useful to measure everything and write it down, or even do a rough sketch so that once you start in CAD and "get in the zone" you don't have to stop to measure stuff, well it works for me.....

The main measurements you will need are the size of the PCB, and the space of the buttons from the side and bottom. I got some rather odd measurement as it was obviously drawn in Inches, It would be easy enough to draw the box in inches, but as I live in a metric country, and my CAD program is set up in metric and it would likely confuse some of my students, Ive just stuck with the metric system.

It is helpful if you have a CAD drawing of the PCB then draw your box around it. the pictures all have notes so click on the first one and use your arrow keys to follow along.

Next we need to draw the sides and screw holes. Sometimes the round corners can cause issues, but click on the pictures and follow along and ill will show you how to fix it.

Now we have to make a DXF file for the laser cutter, also don't forget to save your engineering drawing so you can modify it later if you want.

Next we have extrude and export the drawing to an STL file. Click on the first picture and follow along.

After painting you can assemble your project, and as long as it has been drawn accurately it should all fit perfectly. You can use small screws for buttons or 3D print them also.

The Camo paint turned out really well and is easy to do

Now if you have that 4bits clock kit you could just cheat and use the files here.... If you can't show me your CAD drawings Ill know you cheated!