In a recent episode of Elektor Lab Talk, engineer Saad Imtiaz gave a detailed walkthrough of how to design 3D printed custom enclosures for electronics projects — from CAD modeling to print orientation and material choice.

When creating enclosures, Saad recommends starting with a CAD model of your PCB, exported as a STEP (.stp) file from KiCad or other PCB design tools. This ensures mounting holes and connectors align correctly before printing. “If your board has horizontal connectors or screens, plan those early,” he noted, explaining how connector layout influences enclosure shape.

Choosing the Right CAD Software for Your 3D-printed Projects

Saad’s preferred tools include SolidWorks (“€48 per year and worth it for makers”), Siemens Solid Edge (free community edition), and Onshape, a browser-based option that requires no installation. He also highlighted Shapr3D for quick edits on iPad or Mac — ideal when prototyping on the go.

Different CAD programs can exchange data easily via STEP files, though STL files are meant for printing only. Saad also recalled early days with Rhino and Google SketchUp but said modern tools offer better PCB integration and mechanical accuracy.

Printing and Strength Considerations

For most hobbyist use cases, FDM printing is still the best option. Resin-based methods like SLA or SLS provide finer detail but come with higher cost and complexity. Saad recommends using a 3 mm wall thickness for robust, field-ready designs and adding fillets around mounting points to prevent cracking.

To make 3D prints stronger, he prints parts at a 45° angle rather than stacking layers vertically. “That way, the part can handle stress better and the layers bond more securely,” he explained. Adding small interlocking grooves between top and bottom halves helps prevent slippage or warping due to temperature changes.

From Printing to Molding

Responding to a viewer’s question about scaling up to injection molding, Saad explained that SolidWorks can help assess whether a part is moldable — meaning it can be split cleanly into two mold halves without undercuts. Simple enclosures are easy to mold, but side holes or complex indentations can complicate tooling and raise costs.

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