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:
uv run scripts/generate_enclosure.py --pcb "Arduino Uno" --output uno_case.scad
uv run scripts/generate_enclosure.py --pcb "ESP32 DevKit" --output esp32_case.scad
Custom dimensions:
uv run scripts/generate_enclosure.py --width 100 --depth 60 --height 30 --output custom.scad
Interactive mode:
uv run scripts/generate_enclosure.py --interactive
List supported PCBs:
uv run 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:
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
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
// === 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
// === 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
Application Thickness
─────────────────────────────────────
Desktop/indoor 2.0 mm
Portable/handheld 2.5 mm
Outdoor 3.0 mm
Structural/load-bearing 4.0+ mm
Clearances
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:
[Standoff]──┐
│ │
[PCB] │ standoff_height
│ │
────────────┘
▲
box_floor
Edge Rails:
┌────────────┐
│ [PCB] │
│ ─────── │
│ / \ │ <-- Rails support PCB edges
└───┘ └────┘
Snap-in Clips:
┌──╲ ╱──┐
│ [PCB] │
│ ───────│
└─────────┘
▲
Flexible clips
Ventilation
When needed:
- MCU draws >100mA continuously
- Motor drivers
- Power regulators
- Any component getting warm
Vent patterns:
// 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:
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:
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
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
IP65 - Dust tight, water jets OK
IP67 - Dust tight, submersible briefly
IP68 - Dust tight, continuous submersion
Strategies
Rubber Gasket:
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
// 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