Customizable Rugged Waterproof Box

thingiverse

Human: (edit 1/27/2019, Improved components: Latch Arm v2.stl is slightly longer, making it easier to open. Latch cam v2.stl is now symmetric, but functionally identical. New type of hinge; hinge_single_axis.stl, if you use this, only the top half of the hinge will open, making the box less floppy when it is open. Added assembly diagrams.) (edit 3/10/2019, I've have made the lugs tougher by adding more material on the outside of the screw holes, roughly doubling the thickness there. This should also help them print better by avoiding very short extrusions. Only the boxes changed, the fixtures are the same. f3d files are also updated. I've also put the old f3d files back, since they behave a bit differently when out of range parameters are put in, see the comments for more detail.) (edit 3/24/2019, I've added an f3d file for customizing the o-ring.) This rugged box features hinges and latches that can be made waterproof by printing a seal in flexible filament or cutting a large 2mm thick o-ring to the appropriate length. A version without the seal ring is also available. The latches and hinges are secured with 20mm M3 screws, requiring eight screws in total. The hinges are springy, applying static pressure to the seal when the box is closed. Two types of latch exist: a simple clip and a two-part mechanism acting as a cam that applies significant static pressure to the seal. You can swap out the latches after assembly, allowing you to try both options and choose your preference. Here's a video demonstrating the latch operation: https://youtu.be/6OlaYMMWIgA To adjust the mechanism's tightness, scale the x&y size of the latches or hinges in your slicer (a 2% change makes a significant difference). Two thickness options exist for the seal: one thinner and one thicker. The thinner seal takes less force to close, suitable for keeping dust and spray out. Using the thicker seal and tight latches can make the box waterproof. I printed this with three perimeters, the thick seal, and tight latches, then submerged it under 10cm of water for 10 minutes without any leakage (with a thinner seal about 10ml of water leaked in during the same test, making it still pretty good). Printing the Box: Recommend using 3 perimeters to improve wall strength. Use 5 or more top and bottom layers to ensure water tightness and at least 30% infill for strength on the bottom and top. Both PLA and PETG work well. Printing the Latches and Hinges: Use three perimeters and >30% infill. I recommend using PETG, but PLA also works fine after printing. However, there's a risk it will creep over time, making it looser and degrading seal quality. Print both sizes to decide on tightness or looseness. Printing the O-Ring: The challenge lies in ensuring compliance for a good seal. I used TPU with 1 perimeter and no infill (a cross-section photo above). Be cautious not to under-extrude, as water could leak through the printed seal itself. A smooth bed, such as glass, will help achieve a good seal. Assembly: Orient hinges and latches according to cross-section images, ensuring hole alignment on the latch and opposite side. If using an electric screwdriver, go slowly to avoid melting holes with friction. Install the seal with the domed surface facing into the groove and flat surface exposed. Customization: You cannot scale the box directly in your slicer or screw holes will no longer be correct. I've included fusion 360 f3d archive files that are parameterized for adjusting size by changing Length, Width, and Height parameters. You can also edit the "Path" sketch to make non-rectangular boxes or add more tabs if needed. Use the "low height" version of the f3d file for heights below 38mm due to slightly different filleting on the tabs. Enjoy your customization, and please share any customizations you make.