i3 prusa PSU safety cover with mains socket / fuse /switch

thingiverse

This is a very safe enclosure for the PSU (check out the screenshot and one cutaway to see internal compartments of this enclosure). But first, a note. I made a silly mistake when printing and instead of rotating the part before printing, I flipped it, causing it to be mirrored. The socket is designed to be in the far end corner; however, I printed it poorly. I might reprint it one day. You can't touch the connectors even when you try to (the bottom is concealed). It's small and not sticking out nor square (there is no edge on the bottom to hit by accident), in case you will tilt the printer there is plenty of clearance so this enclosure will not get abused or damaged when you will move the printer around. The mains socket is physically separated in its own compartment. If any wire gets loose, it won't touch the PSU connector (it's protecting against the case where a live wire could touch the + DC terminals). The mains socket is touching the PLA barrier and the PLA barrier is touching the outer PSU case. This means there is no give when someone tries to yank the power cable. Still, I wouldn't recommend it, but it's firm against the case, and it's insulated from the CASE or the connectors. The PSU has a cover for the connectors; when this cover is on the PSU, it's physically impossible to open this cover (you can't reach it by hand, but even vibrations will not open it because this case is in its way). Small notches will keep the mains socket secured. Tripping over the power lead should detach from the socket without damaging anything and without stressing the connectors in the PSU. In a worst-case scenario where the force is strong enough to yank and damage the case, you are still protected by the physical separation of the compartments, etc. It's plastic so if you want you can destroy/damage it, but I think I made the most I could and from all possible issues I could encounter this enclosure is covered (pun intended). It has space for a second compartment and a hole for a switch (there is a version without the hole), which is for future upgrades. I'm working on software OFF feature where PSU can be turned off after print is done, and the switch can enable/disable this feature. There is a hole at the top to access the second compartment. This hole is then against solid metal when the cover is on and is 90 degrees away from the connectors so it's safe to have an access hole on the top. The wires even when they get loose will not move around the compartments. The wires from the mains compartment need to pass to the second compartment and then to the bottom hole to get out of the case (check the cut screenshot to see bisected inner compartments). Because the wires are physically constrained, I hope the vibrations while printing will have very little effect on the connections in the long term. It feels to me as pretty solid/rigid cover. Even though it has a lot of material around to make a good and strong fit around the case, it still doesn't block the front venting holes. It's designed to be used with this mains socket: http://www.ebay.ie/itm/IEC-Mains-Male-Female-Connector-Entry-Module-Fuse-EMI-Filter-Switch-/231966537139 I have a filament fan, so I was able to print everything like this without any support. You need to rotate the object by 180 degrees around the X axis before printing. Used 0.3mm layer height and with 3 bottom and 3 top solid layers. The infill can be anything; even 100% will not make much difference because with these settings there is probably only one layer where it makes a difference. A lot of the model are just perimeters or solid bottom/top layers. The pass-through holes for the cables create small bridges first and they are closed first, and then the top cover is printed. So I made a few arrangements to allow decent printing without support structures.