The enclosure was designed with Rhino, which is currently available for free on OS X while they are testing and developing the app.
Before designing an enclosure, we had to measure every component we were sticking inside. In theory, different devices are built using their local measurement system (metric everywhere except for the USA). In practice, we found that every device came to a fairly round metric value in millimeters, even the Blue Snowflake microphone.
There are mainly two kinds of measurements we had to make: side lengths, and mounting hole positions. To make all these measurements we used a standard digital vernier caliper. For side measurements, it’s helpful to get a basic bounding box of the area that the component occupies. This will keep your components from hitting each other once you place them inside the enclosure. For the mounting hole positions, it’s important to accurately measure the hole diameters or you might create something that’s too loose or tight for the component. Instead of adding or removing small amounts from your measurements to account for design features like tight and loose fit, use your first pass at measuring to create a set of measurements that are as accurate as possible. Later it’s possible to revise these measurements after printing material tests.
When measuring mounting holes, measure them all from the same reference location rather than relative to one another. This keeps your measurement errors from accumulating.
The hardest component to measure was the Blue Snowflake which had three mounting holes in a circle that seemed to be at non-grid positions. To measure these, we measured the distance between the center of the three holes and created a triangle with those side lengths. In the end, we didn’t mount the Blue Snowflake using those holes.