3D Printing

3D Printed Parts

Parts are designed to be 3D printed with FDM based machines. STL files are oriented to print "as is". Machines with dual extrusion or single extrusion setups are listed below with parts name and description. Parts require tight tolerances that might need adjusting slice setting. Reference the suggested settings below.

CURA Slicing

Parts were sliced using Ultimaker's CURA software and tested with an Ultimaker 3 and Flashforge Inventor II. The kit requires a minimum build volume of 50mm x 50mm x 190mm. No support material is necessary for any of the parts. Double check parts are positioned in the center of the build plate before printing. 

Settings

Use these settings as reference. Values listed were used in Ultimaker's CURA slicing software.

  • 0.2mm Layer Height / 0.4mm nozzle
  • 0.38mm Line Width (inner & outer widths)
  • 40mm/s printing speed
  • 20% infill
  • Supports: No

Parts list

  • bottom.stl – This has a spot for the 1200mAh battery
  • cover.stl – Fits the button pad and metal tactile button
  • frame.stl – Had holes for panel mounted button and switch
  • pcb mount.stl – Fits Feather using M3 holes for M2.5 screws
  • tray.stl – Secures NeoTrellis PCB and metal tactile button

Heat Set Inserts

Frame.stl features four mounting holes sized for these M3 heat set inserts. You'll need to install four inserts by heat press installation using a soldering iron. For great results, use a special installation tip. For more info on how to install heat set inserts, check out our guide.

Installing Heat Set Inserts

The inserts should be installed from the bottom of the part. Orient the frame so the flat surface is facing up. Place an insert on top one of the mounting tabs. The edge without the knurling should press fit into the hole. This will hold it in place while installing. Heat up your soldering iron to 380ºC. Insert the tip of the iron into the insert to heat it up for a few seconds. Gently press down to install the insert until it's flush with the bottom surface. Slowly pull out the tip from the insert. Allow a few seconds too cool before proceeding to the remaining tabs. 

Mounting Tabs

The tabs are approximately 4mm thick so they should be level with the length of the heat set inserts.

Heat Sets Installed

Proceed to install heat set inserts into the remaining mounting tabs. Take your time with these! It's important to be cautious as the part could be damaged if inserts are pressed too deep. If you're new to this, perhaps try on some test parts first. 

Designing Things

The Fusion 360 source file is included and features original sketches and feature timeline along with easily editable user parameters. The parts can further be separated into small pieces for fitting on printers with smaller build volumes. Note: the STEP file is included for other 3D surface modeling programs such as Onshape, Solidworks and Rhino.

Layer by Layer

Interested in CAD tutorials? Check out the playlist on YouTube – There's over 100 of them! My personal favorite is the snap fit tutorial for cases and enclosures. 

This guide was first published on Jul 16, 2019. It was last updated on Jul 16, 2019. This page (3D Printing) was last updated on Sep 16, 2019.