3D Printing a Case

3D Printed Parts


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

Slice Settings

 

Use these settings as reference. Values listed were used in Ultimaker's CURA 3.X slicing software.

  • 0.2mm Layer Height / 0.4mm nozzle
  • 0.35mm Line Width (inner & outer widths)
  • 60mm/s printing speed
  • 20% infill
  • Supports: Yes

Flat Head Screws

Here are a list of screws used to secure the PyPortal and case parts.

PowerBoost: M2.5x5mm

PyPortal and bracket: M3x5mm

Case lid, button: M2x5mm

Display Bracket Assembly

 

Before mounting our display, we'll need to secure the bracket with two M3x5mm long screws. 

Next, we'll lay the PyPortal on top of the standoffs on the Bracket part. The standoffs with the half cuts will align with the display on the PyPortal. 

Use four M3x5mm screws to mount the PyPortal to the bracket part.

PowerBoost Connections

 

To reduce the amount of wires, we trimmed the STEMMA cable short and used female jumper wires to create a "Y" splitter for the ground connection.

We'll need to add jumper wires to the barrel jack to allow us to mount it through the cases Back lid part.

Here are the wire measurements for each component to solder to the PowerBoost.

USB: 65mm

DC Barrel: 180mm

 Slide Switch: 180mm

Mount Display

 

Align the bracket to the two standoffs inside the case. Fasten both screws to secure the display to the case.  

Mount PowerBoost

 

Next, we'll align the USB micro port on the PowerBoost to the edge of the case. Use M2.5x5mm screws to secure to the standoffs. The included USB-A press fits into the three walls on the edge of the case.

 

Arcade Button Holder


Our 3d printed key cap replaces the key cap on the arcade button. We'll need to disassemble the arcade button as detailed in the Adafruit NeoPixel Arcade Button Guide to remove the button housing to fit the printed key cap. 

The Key Hold part is secured to the case with two M2x5mm screws.

Speaker 

 

After soldering the Pico Blade 2-pin Cable to the speaker, you'll want to coil the wires to keep the wire clutter down.

Align the two tabs on the speaker to the slot on the circular opening on the case. Angle the speaker and press fit into place.  

 

Barrel + Slide Switch

 

The optional barrel jack mounts to the Back lid part. Remove the metal ring around the barrel, pass through the opening and then rethread the metal ring to secure the barrel. 

The Slide Switch press fits between the three walls on the Back lid part.

 

Battery 

Attach the battery to the case with a small strip of double stick foam tape. 

 

Mount Key

 

Finally, align the printed key cap to the mounted actuator. Press fit and test out an alarm! 

You can set the alarm by tapping buttons on the screen and use the UI to either turn it on or off.

PyPortal makes building IoT projects fun and CircuitPython makes it easy to learn how to program hardware. 

This design has a retro inspired look that fits well with the aesthetic!

This guide was first published on Mar 27, 2019. It was last updated on Mar 27, 2019. This page (3D Printing a Case) was last updated on Oct 21, 2019.