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Low profile 3d printed 6S enclosure

Just wanted to document my latest enclosure that is entirely 3d printed. I tried the two box and connecting wires but it looked awful and the boxes were too big so a lot of space wasn’t used. I started working on a 3d printed enclosure, the first verision snapped even though it was ABS. My board is relatively flexible. I would guess the top and bottom layers are bamboo with some maple/oak on the inside, because it has some give with my weight on it but not as much as a known full bamboo board does. As I was designing version 2 I thought of ways to alleviate the flexing stress so I created a joint that sort of “pivots” when weight is applied.

CAD design of the flexing joint:

Full Board:

Me with no weight on the board:

With weight (notice flexing at joint):

Used T nuts, not a fan because I am going to re apply clear griptape and they are kind of ugly, however they dont strip out like brass inserts.

Still going to attach a hinged door for access to charging port

I was very shocked of how small I was able to get it definitely one of the smallest enclosures I’ve seen that isn’t cut into the deck. It holds a VESC, 2 3S 5000mah zippy batteries, a receiver, and appropriate wiring. Drove around the neighborhood and still no cracking (crossing fingers). Will be interesting going back to school were the roads are much worse.

8 Likes

This is the problem with flexible bamboo decks.
This is why boosted split the battery and electronics into 2 separate enclosures and put them as close to the trucks as possible and connected them with wires under the grip tape.
You might try that or get a maple deck that won’t flex.
Anyway your enclosure looks really clean!
You could probably sell those here if you offered different sizes or custom.

I love it!! That enclosure looks incredible. Did you happen to post it on thingiverse? If so, a link would be greatly appreciated. I am planning a build for a friend, and I think this would be perfect (Also using 2 x 3s Zippy 5000Mah).

I tried printing a couple. ABS and PLA. They were just too brittle unfortunately

@Namasaki
Yea I have some regret getting a bamboo deck, but I really love the finish of bamboo aesthetically speaking. It’s got nowhere as much flex as an all bamboo board but enough to cause flat enclosures a problem. As for selling them, I still don’t have confidence that it wouldn’t break over time so no sales yet, and they take FOREVER to print.

@anorak234
I could post it on thingiverse, however the curvature is custom to the board so it might not fit to your board.

@stuxtruth
Yea I have had a really hard time to get ABS printing right, next time I might use PET less warping, and probably less brittle. However I can forcefully bend the enclosure with a little give I am just worried about long term vibrations.