Print the joint before you print the box
The enclosure is mine end to end — modelled in SolidWorks and drawn for FDM printing, through two full revisions. Every interface that could bite got its own throwaway coupon first: a hinge, the charger port, the screen bezel, the latch tab, the power switch, and a housing for the on/off button. Each one printed, offered up to the real component, and binned.
Only once those passed did a full V2 assembly get committed to a multi-hour print. The dates below are the CAD files themselves — six coupons in five days, five of them in a single session, then the assembly.
- Main case + lid, rev 1
- 17–22 Aug
- Hinge coupon
- 18 Aug
- Charger-port coupon
- 18 Aug
- Latch-tab coupon
- 18 Aug
- Power-switch coupon
- 18 Aug
- On/off button housing
- 18 Aug
- Screen-bezel coupon
- 22 Aug
- Full V2 assembly
- 24 Aug