Enclosure Designer
Creates 3D-printable enclosures for electronics projects.
Resources
This skill includes bundled tools and templates:
- •scripts/generate_enclosure.py - Parametric OpenSCAD generator with PCB database
- •assets/basic-template.scad - Customizable OpenSCAD template
Quick Start
Generate for specific PCB:
bash
uv run --no-project scripts/generate_enclosure.py --pcb "Arduino Uno" --output uno_case.scad uv run --no-project scripts/generate_enclosure.py --pcb "ESP32 DevKit" --output esp32_case.scad
Custom dimensions:
bash
uv run --no-project scripts/generate_enclosure.py --width 100 --depth 60 --height 30 --output custom.scad
Interactive mode:
bash
uv run --no-project scripts/generate_enclosure.py --interactive
List supported PCBs:
bash
uv run --no-project scripts/generate_enclosure.py --list
When to Use
- •"I need a case for my project"
- •"How do I make an enclosure?"
- •"Design a box for my Arduino"
- •User has working circuit, needs housing
- •Preparing for deployment/presentation
Design Workflow
Step 1: Gather Measurements
Ask user for:
code
1. Main board dimensions (L × W × H in mm) 2. Component clearances (tallest component height) 3. Connectors/ports that need access (USB, power jack, etc.) 4. Mounting holes (positions, diameters) 5. Any displays, buttons, LEDs that need cutouts 6. Environment (indoor/outdoor, waterproof?)
Step 2: Design Parameters
code
Enclosure Type: [Box/Clamshell/Snap-fit/Screw-mount] Material: [PLA/PETG/ABS] Wall Thickness: [2-3mm typical] Mounting Style: [Standoffs/Clips/Rails] Ventilation: [None/Slots/Holes] Access: [Top-remove/Front-panel/Side-openings]
Step 3: Generate Design
Choose approach:
- •Parametric OpenSCAD - Full customization
- •Pre-made generator - Quick results
- •Manual Fusion360/TinkerCAD - Visual design
Parametric OpenSCAD Template
Basic Project Box
openscad
// === PARAMETRIC PROJECT BOX ===
// Customize these values for your project
// Internal dimensions (mm)
inner_length = 70; // X axis
inner_width = 50; // Y axis
inner_height = 30; // Z axis (internal depth)
// Wall and tolerances
wall = 2.5; // Wall thickness
lid_tolerance = 0.4; // Gap for lid fit
corner_radius = 3; // Rounded corners
// Mounting standoffs
standoff_height = 5; // PCB clearance from bottom
standoff_dia = 6; // Standoff outer diameter
screw_hole_dia = 2.5; // M2.5 screw hole
// PCB mounting hole positions (from corner)
// Measure from your board!
pcb_holes = [
[5, 5], // Bottom-left
[65, 5], // Bottom-right
[5, 45], // Top-left
[65, 45] // Top-right
];
// Lid attachment
lid_screw_dia = 3; // M3 screws
lid_screw_positions = [
[5, 5],
[inner_length-5, 5],
[5, inner_width-5],
[inner_length-5, inner_width-5]
];
// Cutouts (add as needed)
usb_cutout = true;
usb_x = 35; // Center position
usb_width = 12;
usb_height = 8;
// === MODULES ===
module rounded_box(l, w, h, r) {
hull() {
for (x = [r, l-r])
for (y = [r, w-r])
translate([x, y, 0])
cylinder(h=h, r=r, $fn=32);
}
}
module standoff(h, outer_d, inner_d) {
difference() {
cylinder(h=h, d=outer_d, $fn=24);
cylinder(h=h+1, d=inner_d, $fn=24);
}
}
module box_base() {
outer_l = inner_length + 2*wall;
outer_w = inner_width + 2*wall;
outer_h = inner_height + wall; // Bottom wall
difference() {
// Outer shell
rounded_box(outer_l, outer_w, outer_h, corner_radius);
// Inner cavity
translate([wall, wall, wall])
rounded_box(inner_length, inner_width, inner_height+1, corner_radius-wall);
// USB cutout
if (usb_cutout) {
translate([wall + usb_x - usb_width/2, -1, wall + standoff_height])
cube([usb_width, wall+2, usb_height]);
}
}
// Add standoffs
for (pos = pcb_holes) {
translate([wall + pos[0], wall + pos[1], wall])
standoff(standoff_height, standoff_dia, screw_hole_dia);
}
}
module box_lid() {
lid_wall = wall - lid_tolerance;
outer_l = inner_length + 2*wall;
outer_w = inner_width + 2*wall;
lip_h = 5; // How deep lid inserts
// Lid top
rounded_box(outer_l, outer_w, wall, corner_radius);
// Lid lip (inserts into box)
translate([wall + lid_tolerance, wall + lid_tolerance, -lip_h])
difference() {
rounded_box(inner_length - 2*lid_tolerance,
inner_width - 2*lid_tolerance,
lip_h, corner_radius - wall);
}
}
// === RENDER ===
// Uncomment one at a time for printing:
box_base();
// translate([0, inner_width + 20, 0]) box_lid();
Adding Cutouts
openscad
// === CUTOUT LIBRARY ===
// Round hole (for buttons, LEDs)
module round_cutout(x, y, z, diameter, depth) {
translate([x, y, z])
rotate([90, 0, 0])
cylinder(h=depth, d=diameter, $fn=32);
}
// Rectangle (for displays, SD cards)
module rect_cutout(x, y, z, width, height, depth) {
translate([x - width/2, -0.1, z])
cube([width, depth + 0.2, height]);
}
// Slot (for ventilation, cables)
module slot_cutout(x, y, z, width, height, depth) {
translate([x, y, z])
hull() {
translate([0, 0, 0])
cylinder(h=depth, d=height, $fn=24);
translate([width-height, 0, 0])
cylinder(h=depth, d=height, $fn=24);
}
}
// OLED display cutout (128x64 module)
module oled_cutout() {
// Visible area
rect_cutout(inner_length/2, wall, inner_height - 15, 26, 14, wall+1);
// Mounting holes (if needed)
}
// Common connector dimensions
usb_micro = [8, 3]; // USB Micro
usb_c = [9, 3.5]; // USB-C
barrel_jack = [12, 12]; // 5.5mm DC jack (round)
sd_card = [15, 3]; // SD card slot
Online Generators (No CAD Needed)
Ultimate Box Maker (Thingiverse)
https://www.thingiverse.com/thing:1264391
Parameters:
- •Enter internal dimensions
- •Choose wall thickness
- •Select lid type (snap/screw/slide)
- •Add ventilation slots
- •Download STL
Parametric Box by Heartman
https://www.thingiverse.com/thing:1355018
Good for:
- •Simple project boxes
- •Snap-fit lids
- •Basic customization
FreeCAD + Parametric Enclosure
- •Install FreeCAD
- •Use Spreadsheet workbench for parameters
- •Generate enclosure with formulas
- •Export STL
Common Board Dimensions
Arduino Family
| Board | L × W × H (mm) | Mounting Holes |
|---|---|---|
| UNO R3 | 68.6 × 53.4 × 15 | 4 holes, 3.2mm |
| Nano | 45 × 18 × 8 | 2 holes, 1.5mm |
| Mega 2560 | 101.5 × 53.4 × 15 | 4 holes, 3.2mm |
| Pro Mini | 33 × 18 × 5 | None standard |
ESP32 Family
| Board | L × W × H (mm) | Mounting Holes |
|---|---|---|
| DevKit V1 (38pin) | 55 × 28 × 10 | None (use clips) |
| DevKit V1 (30pin) | 49 × 26 × 10 | None |
| NodeMCU-32S | 51 × 25 × 10 | 2 holes, 3mm |
| ESP32-CAM | 40 × 27 × 12 | 2 holes, 2mm |
Raspberry Pi Pico
| Board | L × W × H (mm) | Mounting Holes |
|---|---|---|
| Pico/Pico W | 51 × 21 × 4 | 4 holes, 2.1mm |
Common Modules
| Module | L × W × H (mm) | Notes |
|---|---|---|
| SSD1306 OLED 0.96" | 27 × 27 × 4 | 4 corners 2mm |
| BME280 | 15 × 12 × 3 | 2 holes 2mm |
| SD Card | 42 × 24 × 5 | 4 corners 2mm |
| TP4056 | 26 × 17 × 4 | None |
| 18650 holder | 77 × 21 × 19 | Varies |
Design Guidelines
Wall Thickness
code
Application Thickness ───────────────────────────────────── Desktop/indoor 2.0 mm Portable/handheld 2.5 mm Outdoor 3.0 mm Structural/load-bearing 4.0+ mm
Clearances
code
Component Add clearance ───────────────────────────────────── PCB to wall 1-2 mm USB/connector 0.5 mm extra per side Moving parts 2-3 mm Lid fit 0.3-0.5 mm gap
Mounting Strategies
PCB Standoffs:
code
[Standoff]──┐
│ │
[PCB] │ standoff_height
│ │
────────────┘
▲
box_floor
Edge Rails:
code
┌────────────┐
│ [PCB] │
│ ─────── │
│ / \ │ <-- Rails support PCB edges
└───┘ └────┘
Snap-in Clips:
code
┌──╲ ╱──┐
│ [PCB] │
│ ───────│
└─────────┘
▲
Flexible clips
Ventilation
When needed:
- •MCU draws >100mA continuously
- •Motor drivers
- •Power regulators
- •Any component getting warm
Vent patterns:
code
// Slot pattern (easy to print, good flow)
for (i = [0:5]) {
translate([10 + i*8, wall/2, 10])
slot_cutout(20, 3, wall+1);
}
// Honeycomb (looks cool, harder to print)
// Use pre-made pattern from Thingiverse
Print Settings
Material Selection
| Material | Pros | Cons | Best For |
|---|---|---|---|
| PLA | Easy to print, cheap | Weak to heat (>50°C) | Indoor projects |
| PETG | Heat resistant, strong | Stringing, harder | Outdoor, functional |
| ABS | Heat resistant, tough | Warps, fumes | Professional |
| ASA | UV resistant | Like ABS | Outdoor long-term |
Recommended Settings
PLA Enclosure:
code
Layer height: 0.2mm Wall count: 3-4 (for 2-3mm wall) Infill: 15-20% Support: Usually not needed if designed right Bed temp: 60°C Nozzle temp: 200-210°C
PETG Enclosure:
code
Layer height: 0.2mm Wall count: 3-4 Infill: 20-25% Support: Often needed Bed temp: 80°C Nozzle temp: 230-245°C Print slower than PLA
Orientation Tips
code
Print box BASE standing up (opening facing up) - No supports needed - Good surface finish inside - Strong walls Print LID flat (top surface down) - Smooth exterior surface - May need supports for cutouts
Waterproofing
IP Rating Guide
code
IP65 - Dust tight, water jets OK IP67 - Dust tight, submersible briefly IP68 - Dust tight, continuous submersion
Strategies
Rubber Gasket:
code
Add groove in lid for O-ring:
┌───╔═══════╗───┐
│ ║O-ring ║ │
│ ╚═══════╝ │
│ [box] │
└───────────────┘
Cable Glands:
- •Use PG7/PG9 cable glands for wires
- •Drill precise holes, thread in glands
- •Seal with silicone if needed
Conformal Coating:
- •Spray PCB with conformal coat
- •Protects electronics inside box
Example: ESP32 Weather Station Enclosure
openscad
// ESP32 Weather Station Enclosure // Components: ESP32 DevKit, BME280, SSD1306 OLED, 18650 battery // Internal dimensions (measured from components + clearance) inner_length = 80; inner_width = 55; inner_height = 50; // Room for battery under PCB wall = 3; // Outdoor = thicker walls // ESP32 on standoffs esp_standoff_h = 25; // Above battery esp_holes = [[5, 5], [5, 50], [52, 5], [52, 50]]; // OLED window position (top of enclosure) oled_x = 40; oled_y = 15; oled_w = 28; oled_h = 16; // BME280 vent hole bme_vent_x = 70; bme_vent_y = 30; bme_vent_dia = 8; // USB access usb_x = 30; usb_y = inner_height - 15; // Generate with above parameters...
Troubleshooting
| Problem | Cause | Solution |
|---|---|---|
| Lid too tight | Tolerance too small | Increase to 0.5mm |
| Lid too loose | Tolerance too large | Decrease, add clips |
| Screws strip | Holes too large | Use proper thread inserts |
| Parts don't fit | Measurement error | Remeasure, print test piece |
| Weak walls | Too thin, low infill | Increase wall count |
| Warping | ABS, big flat surfaces | Use brim, enclosure, PETG |
Resources
- •OpenSCAD: https://openscad.org
- •Thingiverse Customizer: Parametric designs
- •Printables: More enclosure designs
- •McMaster-Carr: Reference for hardware dimensions