Customizable Rugged Waterproof Box

cults3d

This is a rugged box with hinges and latches that can withstand harsh conditions. To ensure it remains watertight, simply print a seal in flexible filament like TPU or cut a large 2mm thick o-ring to the right length. There's also an option without the seal ring. The latches and hinges are held securely by 20mm M3 screws, requiring eight in total. The hinges are designed with a springy mechanism that applies static pressure to the seal when closed. You can swap out the latches after assembly, allowing you to try both types and choose your preference. There's a video showcasing the latch operation available online: https://youtu.be/6OlaYMMWIgA To adjust the tightness of the mechanism, scale the x&y size of the latches or hinges in your slicer - even a 2% change can make a significant difference. You also have two thickness options for the seal: the thinner one is perfect for keeping dust and spray out, while the thicker seal combined with tight latches makes it waterproof. I printed this box using three perimeters, thick seal, and tight latches, then submerged it in 10cm of water for 10 minutes without any leakage. The thinner seal allowed about 10ml of water to leak in during the same test, still a pretty good result. Printing the box: I recommend printing with three perimeters to improve wall strength. Use five or more top and bottom layers to ensure it's watertight, and at least 30% infill for the bottom and top. Both PLA and PETG work well. Printing the latches and hinges: Use three perimeters and over 30% infill. I recommend using PETG, but PLA also works fine after printing. However, there's a risk that it will creep over time, making it looser and degrading seal quality. I suggest printing both sizes at first to decide how tight or loose you want the closure to be. Printing the o-ring: The challenge here is ensuring it's compliant enough to form a good seal. I used TPU with one perimeter and no infill, but make sure not to under-extrude, as water could leak through the printed seal itself. A very smooth bed will help get a good seal. Assembly: Orient the hinges and latches according to the photos, carefully lining up with the hole in the latch and the opposite side. If using an electric screwdriver, go slowly to avoid melting the holes with friction. I recommend installing the seal with the domed surface facing into the groove and the flat surface exposed. Customization: You can't scale the box directly in your slicer or the screw holes will no longer be correct. I've included Fusion 360 F3D archive files that are parameterized, allowing you to adjust size by changing Length, Width, and Height parameters. You can also edit the "Path" sketch to make non-rectangular boxes. Add more tabs if needed for additional hinges or latches. There are two versions of the F3D files: use the "low height" one with slightly different filleting on the tabs if you want to use heights below 38mm. Enjoy, and feel free to share any customizations you make!