Duet Wifi controller box attaches to 2020 extrusion

thingiverse

This control box is designed for mounting a Duet Wifi board on a 3D printer or other machine that uses 2020 aluminum extrusions. Originally, this was a remix of Greg24's Duet Wifi mount/cover found at http://www.thingiverse.com/thing:1920401. However, as I continued to work on it, I made extensive modifications and encountered issues when converting the box from having a removable bottom to a removable top. In the end, I started over from scratch. Everything about my box is different, including dimensions, cable hole design, board mounting method, airflow vision (I have extensive venting on the opposite side of fans with a solid lid), etc. Additionally, I added a side rail that allows this box to be screwed down onto 2020 extrusions. I deliberately left the corner chamfer of the ledge around the top without holes for securing the lid. This is because it's up to the user to decide on the type of fastener they want to use. Drilling holes through the lid into that chamfer is a simple matter for whatever size/shape of screw you choose. This design is incomplete in one respect: I've created screw blocks for securing the plastic cable conduit inside the mounting box, but haven't designed the matching plastic pieces that would actually screw down onto these. Now that my box has started getting installed into my D-bot, the plastic conduit fits tight enough that it may not be strictly necessary. I might not bother. As a tribute to Greg24's box, I've included an alternate lid that I snipped from his original Duet Wifi mount. This preserves his diagonal vents but has dimensions allowing it to serve as the lid for my box. I do not recommend using the vented lid at present because it could result in insufficient airflow under the Duet Wifi board, where a majority of heat is dissipated from stepper driver chips and power mosfets. My solid lid allows airflow directly from 40mm fans across the Duet Wifi board (both sides) and out through vents on the front face of the box. Update 13 March 2017: I've added a new version of the controller box featuring four 12mm holes (accommodating 1/2" plastic conduit) on the back side, which has the two fans. This was due to realizing that my printer's most sensible wiring had more cables coming into the back of the box than anticipated. To maintain neatness in routing conduits from different areas of the printer up to the control box and keep wires separated by function at their entry point, four holes simply made sense. Printer Settings: - Brand: Wanhao - Printer: Wanhao Duplicator i3 V2 - Rafts: No - Supports: No - Resolution: .2mm layer height - Infill: 40% - Notes: Not much infill is actually used. What little infill there is, I set to 40% because it's over the wide base and I wanted the top layers nice and smooth.