3D Print a Custom Project Box (Without CAD!)

Despite the growth of the 3D printing community over the last decade, there are still a few barriers to entry. One of these barriers is the ability to create custom 3D models. Currently, if you need a custom part (say, an electronics enclosure) your only real option is to design it yourself. There are free CAD programs and great tutorials (e.g. Instructables!) available, but the learning curve is still not trivial. In addition to learning how to use the tools, you also have to understand how to design for additive manufacturing.

To help alleviate this constraint, I've been building a website that allows makers to configure 3D models online to create custom objects. Basically, you can input parameters and the 3D model will update accordingly. When you're done, you can download the model and 3D print it. This way, you get many of the advantages of designing from scratch, without the time or difficulty required. I'm starting with project boxes, because they are a common application, but the process is versatile so I hope to expand to other categories in the future. If you have suggestions for other configurable parts, please let me know in the comments!

Disclaimer: I do sell physical project boxes on the website for people who don't have 3D printers, but that is irrelevant to this instructable. The 3D models I'll be discussing here are completely FREE.

Step 1: Build

Before we get ahead of ourselves, let's build an electronics project! I built this cool PWM controller from andreash79's instructable. I added an indicator LED and an on/off switch, but the rest of the circuit is basically the same. I also opted for perfboard instead of a custom PCB for the sake of convenience.

As you wire everything up, think about how you want your components laid out in the enclosure. Try nesting the major components together before soldering. By doing this, I discovered that I could make the project more compact by soldering the potentiometer to the underside of the board. A bit unconventional, but effective!

Step 2: Measure

Measure the overall size of your project as well as the size and position of any components that will protrude through the enclosure walls. Note that the configurator in the next step accepts dimensions in mm, so either measure in metric or convert.

Try to be as accurate as possible here. Remember: Measure twice, print once!

Step 3: Configure

Make your way over to lightningboxes.com and select a base model that suits your project. I went with the Basic Box for this project. Change the dimensions of the box and add cutouts to match the measurements you made earlier. Don't forget to add enough clearance to assemble everything.

When you're finished configuring your box, click the "Download Model" button to get an STL file of your design.

Step 4: Slice & Print

Open the STL file you downloaded in your favorite 3D slicer program. Orient and slice the model as you would any other. Keep in mind that if you added a large cutout to the side of your box, you may need to use supports to prevent sagging.

Step 5: Assemble & Test

Assemble your new enclosure using M3 or #4 screws. Coarse threads are preferable in 3D printed parts because they "bite" into the plastic better.

Test your project again to make sure no connections were damaged during assembly.

Enjoy!

Step 6: Conclusion

Thanks for reading! If you have questions about Lightning Boxes or ideas for improvement, please let me know in the comments. I'm actively developing the website at the time of this writing, so I'd love to hear any feedback you might have.