Configurable LM2596 case with optional power switch

thingiverse

I designed this to fit any possible need I might come across in my various printer and/or electronics builds. I was inspired by a couple of other models, mostly by this one: https://www.thingiverse.com/thing:4623548, but ended up creating mine completely from scratch. I do not recommend using the online Configurator, but rather suggest just installing OpenSCAD and running the script/configuring the options there. Not to mention some parameters, like the top vent offset, are better tuned while checking the outcome from each setting as you go. I do realize that many people do not want to be bothered with that, so i included 3 STLs of the most common options. 1. Bottom Mount, using tabs with rounded corners, no lip on the lid for the button. 2. Left side Mount, using tabs with rounded corners, no lip on the lid for the button. 3. Right Side Mount, using tabs with rounded corners, no lip on the lid for the button. These all should need minimal, from build plate only, support. I tried to design it to not need any supports, and if no foot is used then supports are almost non-existent. There are 2 places were supports from build plate are useful. 1. If adding a lip to the bottom of the button hole, for better fit of the switch used. I included a picture of what the lip looks like from underneath. It all depends on the switch being used. You can also always just clip off the pressure tabs on the switch to make it fit w/o a lip, or to more perfectly fit your set lip, while still ensuring a thick enough mount point for the switch. If you set the button lip to equal or be taller than the button pad height + the lid thickness, then that essentially "disables" it. 2. When using Left or Right Tab Mounts, the space between the bottom of the case and bottom edge of the tabs will need support I designed the lid mount points within the case itself to not need supports when printing. I included a picture of that detail as well. Some options: The original design included footers that held the case bottom off of whatever it was up against, I assumed to allow more air flow through the bottom vents. These can be enabled/excluded as desired. The bottom vents can also be enabled or excluded, if you want a completely closed case. The same goes for the top vents and also the power switch. If you disable all vents and the power switch, and change the wire inlet option to a diameter of 0 (it is allowed in the code) and use tabs to mount, or no mount at all, then it becomes a completely enclosed case. Bottom mount w/ tabs disabled and footers enabled will basically set it up like the original design. There is also a "catch" key on the back foot that is intended to work alongside the bottom inside mount hole to mount and position the case on a 20mm extrusion frame. The front mount hole can be used with a T-nut and the back catch will fit into the 2020 extrusion to align the case with the extrusion piece. I did include a picture of what that bottom detail would look like. There are object specific as well as more "global" build options. For the global build options you can choose to generate the lid, case or both. You can also set the separation distance on the build plate when generating both together. The Base and Lid have many specific options. I tried to make them as descriptive as possible via the comments that show up in the Customizer. A couple that I will call out are for the lid. Choosing to use a power switch or not. This will remove all attributes of the power switch from the generated model. You can shorten the Base to just the length for an LM, leave the top vents in place and remove the button to make it an LM only case. Top vents have a couple of options, including whether to use them or not. And if including them, what their width and angle orientation is. There is a Y Offset setting that will need to be tweaked if using a positive angle. I found that 0 works well for a -30 angle and 4.5 worked reasonably well for a (+) 30 angle. The angle can be adjusted for many purposes, but I use it mainly if I am mounting the case in a way that I am on the left of it, having the vents tilt away from me means I do not see the direct light in my eyes from the LM (but I can still see the "glow"). The power switch orientation is useful for most switches have a key nub on their outer shell. The setting just moves the notch in the switch opening from one side of the hole to the other, rotating the orientation of the switch that is installed. Notes: I did not intend to use heat set inserts, but rather just thread screw into the posts. It would be easy enough to just change the post diameter to meet the requirements for inserts and use those. I think there may be enough room between the mount post and edge of the case, but I have not tried. I used this switch: https://www.amazon.com/QOFOWIN-Rocker-Toggle-Switch-Marine/dp/B07S8TJ9NG and this LM module: https://www.amazon.com/gp/product/B07VVXF7YX/ But any 20mm switch (that meets your input, not output, voltage requirements) and any LM module will work. Both use standard measurements so they should work without any issue. To-Do: It does not work if the following configuration was used: Case Foot and Mount Tabs both enabled + Case Mount set to Bottom. It places the bottom tabs at the bottom of the case not the bottom of the foot. It would require a bit more coding than just moving the Z placement as the tab thickness, and likely the length, would also need to change to match the foot. As it is a scenario that I do not anticipate running into I didn't bother to code around it. You can still generate the model, but there would be a gap between the bottom of the tabs and whatever the Case (bottom of the foot) is resting on. As an interim spacers could always be used under the tab mounts, if this design was really needed. I hope that this is useful to someone down the road.