DPS5005 Power Supply Case - Laser Cut

thingiverse

This is a recreation of the DPS5005 Power Supply Case by SnappyFPV designed to be laser cut. I had it laser cut by the Ponoko service. The plastic I had it cut out of (polypropylene) would not glue easily. Ultimately the process that worked for gluing it together was to apply cyanoacrylate primer/activator to one side of the joint, apply cyanoacrylate to the other part, and then when they were brought together they would hold a semi-permanent bond. Then to give the join enough strength to hold, I pooled two-part epoxy inside the case to create a bead. These cases were glued together in 2017 and I have been traveling around the world with them in my bag and they have held together well. For anyone who is interested in making one of these, I would suggest that it might be a good idea to modify the design to include a tongue-n-groove/casselated edge to the joins to give them more surface area and a friction connection in addition to the adhesive bond.