I’m having a blast CADding this project in OnShape. It’s a new case for the power supply of my TS-101 soldering iron, with switches and connectors to plug detachable cables for the TS-101 and the fume extractor.
I started with a mock up. Then I CADded the original power supply, and finally modified it to add the control panel. 1/
The original power supply is split in the middle and held by clips. Nobody wants that, so I made a flat base and a cover, and added holders for heat-set threaded inserts.
In addition to the 24V for the TS-101, I need 12V for the fume extractor. In order to avoid accidentally swapping the power cables, I chose 3-pin panel-mount Molex Micro-Fit connectors, and I’ll connect 12V and 24V to different pins. 2/
The Micro-Fit were the smallest-footprint panel-mount connectors that I could find that are oriented, can carry 3 Amps, and cannot be easily shorted by a flying metal part. The other contenders were 5.5mm Barrel jack (can easily be shorted, and are generally crap,) and Mini-XLR (unshrouded pins, easy to short as well, and larger footprint.)
The Micro-Fit protrude a little bit, which I’m not a fan of, so I recessed the control panel. 3/
I would have liked XT-30 or XT-60 connectors, but the footprint of panel-mounts is enormous, and it’s also unshrouded pins on that side.
For the 12V, I’m adding a step-down converter. The ones I found with a small enough footprint don’t have mounting holes, so I experimented quite a lot with how to fasten it to the bottom plate.
I opted for a TPU clip-on holder that I can fix to the case with glue or double-sided tape. I hope it allows me to get the PCB in and out even when glued. 4/
I have to add that any advice is welcome. It’s my first 3D printing project, so I don’t know how it will turn out.
I’m probably over-engineering the TPU holder, but it seems safer than built-in clips made of PLA, or whatever filament I will use to print the case, because I can test different sizes, and it’s less likely to break if I make it too thin.
By the way, which material do you recommend? I’ll be printing at my local maker space, so I have options. 5/
@oscherler I'll be interested to see whether your slicer puts support material on those bottom fillets.
