Yet another Sonoff basic wall box

thingiverse

Yet another Sonoff basic wall box I've seen other Sonoff basic wall boxes around, and I thought it would be a great idea to design my own. The goal was to create one that's easy to print, install, and operate. I took a close look at all the existing Sonoff basic wall box designs and decided to incorporate the best ideas into mine. I didn't directly copy anyone else's work; instead, I just used their concepts as inspiration. Thanks for sparking my creativity! This housing is designed to fit both types of switch plates in the US: toggle switches and Decora switches. I've included a paddle for each style, with a simple push-button design that requires no toggle action. I wanted to make it easy to use the Sonoff board without having to flash firmware or solder tiny wires. That's why I designed this housing to be able to simply drop in the Sonoff board and snap it into place. It's a hassle-free process, and printing is just as straightforward – no bridges, few overhangs, and a flat bottom make it easy to print. The design consists of three parts: the housing, cover, and paddles. I've included one toggle paddle and two Decora paddles, with one featuring a circle on its face. To build this, you'll need a clean and flat build plate. You should have that anyway! Use the two tiny screws provided with the Sonoff to secure either the toggle paddle or Decora paddle to the actuator. I've added a travel limiter to prevent damage to the switch in the Sonoff. The other two screws will attach the cover to the housing. When attaching the paddles, make sure to start tapping the 6-32 plate screw holes slowly and with force. It may take a few turns for the tap to feed through smoothly. To install the Sonoff board, arch the back of the housing slightly to spread open the two ends, then snap in the board. The notches on the corners will hold it securely in place. I turned off the LED light in the app since I don't like its green glow. If you'd like to customize the behavior of the LED, that would be a great feature for future updates. This switch was printed with PLA at 0.2 layer height and 25% infill. You can use any color filament you prefer – perhaps red would be perfect for controlling a garage door or fan! For a garage door application, I recommend connecting a 110v relay to the Sonoff board. Activate "inching" in the app and set the pulse time to 1 second. This will give you a smart phone-controlled garage door for under $10! When working with electrical components, remember to use short pigtails to connect the wires from the Sonoff board to your house wiring. Always kill your breakers before starting any work to avoid potential electrocution hazards – I'm not responsible if anything goes wrong!