Universal DC speed controller PCB enclosure

I fully designed and printed this enclosure for a DC9-55V / 0-40A speed controller PCB and its potentiometer A robust, aesthetic, and practical enclosure for your speed controller
 

It is compatible with the circuit visible in the photos

NB: If you have another PCB with a potentiometer, and the PCB size, hole spacing, and potentiometer hole size (8 mm) are identical, feel free to use this enclosure for another purpose

Compatible PCB dimensions:

Length: 80 mm

Width: 55.70 mm

Hole spacing: 72 mm (length) and 48 mm (width)

Enclosure dimensions:

Total length: 92.60 mm

Total width: 94.60 mm

Height: 37 mm

Fastenings:

• Holes provided for 3.5 mm diameter inserts (3 mm hole)
• Lid, bottom, and PCB are secured with 3.5 mm inserts (to be inserted by heating them into the 3 mm holes)

Required screws:

• Lid and PCB → M2.5 x 5 mm
• Bottom → M2.5 x 6 mm

Project content (4 plates):

Plate 1: Feet

• 4 TPE feet (flexible, not to be put in the AMS)
• Possible to print in other materials if you do not want flexibility

Plate 2: Lid

• Contains 8 ventilation fins
• No support required for printing
• Recommended material: PETG, 100% infill (heat resistance)

Tips: use very dry filament to avoid defects → no problems observed during my prints

Plate 3: Bottom

• Integrated: 4 printed standoffs to support the PCB
• Avoid PLA (heated inserts risk damaging the standoffs)
• Recommended material: PETG
• Fastening: the 4 feet screw through with M2.5 x 6 mm screws

Plate 4: Enclosure body

• Printed in PETG CF (carbon) → very nice finish and lightweight enclosure
• Other materials are possible, but be careful: the circuit can heat up → avoid PLA

Usefulness of supports:

• Lid support
• Maintains the hole for the potentiometer (8 mm) to prevent any deformation

• Groove under the box to accommodate the bottom

   

Recommended: use support filament for the support interface → clean finish and easy removal

Tested with Bambu PLA/PETG support filament → excellent result

Result:

With a very dry filament and the settings as in the project, the rendering is perfect (see photos)

Assembly:

Bonus:

I printed 2 enclosures. The first is straight out of the printer. The second was covered after printing with an effect film, using the hydrographic principle (the enclosure is submerged in a tank of water containing the hydrographic film. Thanks to a chemical activator, the pattern transfers onto the object. It was then removed from the water and carefully dried. The result is visible in the photos marked "Hydro")

Happy printing everyone!

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