Sensor enclosure presentation
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The document describes the process of 3D printing sensor node enclosures. It details the hardware components needed including a low power Arduino, radio transceiver, sensors, batteries, and battery holder. The author modifies an existing battery holder design to accommodate end-to-end batteries. Test prints are done to optimize 3D print settings for the new filament. OpenSCAD is used to design interlocking enclosure compartments which are iteratively printed and tested for fit until completed. The assembled sensor node enclosure houses all components.
Sensor enclosure presentation
- 1. 3D Printed Sensor Enclosure August 23, 2017 John Oliva joliva63@gmail.com
- 2. Background • I am building a home automation system and need sensor and actuator nodes • Hardware and software is ready • Need enclosure(s) for building nodes
- 3. Hardware • Low power version of Arduino
- 4. Hardware (cont.) • NRF24L01+ GFSK radio transceiver
- 7. Software • Arduino library + MySensors
- 8. Sensor Node Components • CPU/Radio board + Software ✔ • Sensor ✔ • Batteries + battery holder • Enclosure
- 9. First Concept Sketch • The design concept is a long narrow enclosure with compartments.
- 10. Batteries + Battery Holder • Low power CPU/Radio runs off 2 AA batteries • Design concept is long and narrow so AA batteries must sit end-to-end. • Since I am looking to 3D print what I can, I will print the battery holder rather than purchase one • Let me check what is available on Thingiverse for the battery holder.
- 12. Battery Holder (cont.) • Designed with OpenSCAD ✔ • I have used this one before ✔ • Design configuration only supports side-by-side for multi- cell. Ruh Roh ✗ • Wait a minute – I know OpenSCAD so I can modify the design ✔
- 13. Battery Holder (cont.) • Original side-by-side version in OpenSCAD
- 14. Battery Holder (cont.) • Modified to support end-to-end + no flanges
- 15. Battery Holder (cont.) • New + old capability via customizer
- 16. 3D Printing Battery Holder • Finally, its time to 3D print something • Wait… I am using a new brand and color of PETG filament • Better make sure I have the settings dialed in properly to get good, strong prints
- 17. 3D Printing Battery Holder (cont.) • Use a really simple object that will print fast to test the slicer settings • Iterate and vary layer height, temperature, speed, etc.
- 18. 3D Printing Battery Holder (cont.) • Rate the results from various combinations to find the sweet spot.
- 19. 3D Printing Battery Holder (cont.) • Export STL for battery holder from OpenSCAD and import into Simplify3D (my slicer)
- 20. 3D Printing Battery Holder (cont.) • Generate GCODE using Simplify3D using sweet spot setting and print!
- 21. 3D Printing Battery Holder (cont.) • Some connectors that work with the design purchased on eBay
- 22. Sensor Node Components • CPU/Radio board + Software ✔ • Sensor ✔ • Batteries + battery holder ✔ • Enclosure
- 24. 3D Printing Enclosure (cont.) • Measure internal parts in order to design the enclosure
- 25. 3D Printing Enclosure (cont.) • Use OpenSCAD and customizer to design enclosures and insertable bottoms – this may take some time to get it right
- 26. 3D Printing Enclosure (cont.)
- 27. 3D Printing Enclosure (cont.) • Design and print clip for connecting compartments
- 28. 3D Printing Enclosure (cont.)
- 29. 3D Printing Enclosure (cont.) • Uh, oh. Too tight.
- 30. 3D Printing Enclosure (cont.) • Better
- 31. Sensor Node Components • CPU/Radio board + Software ✔ • Sensor ✔ • Batteries + battery holder ✔ • Enclosure ✔
- 32. Assembly • All parts printed and ready for assembly
- 33. Assembly (cont.) • Battery, battery holder in compartment
- 34. Assembly (cont.) • All components in compartments
- 35. Assembly (cont.) • Fully assembled
- 36. Future Improvements • Tune dimensions of battery holder and compartments for a better fit • Add fillets to enclosure to strengthen places where walls meet • Experiment with other enclosure configurations – not long and narrow