How to design Custom 3D Printed Cases

The ability to create custom 3D printed cases opens up a vast range of possibilities for protecting, organizing, and enhancing the usability of various tools and gadgets. Especially for the computer case, we can custom 3d printed computer case to make it very personality. In this guide, we will take an in-depth look at the process of designing and manufacturing a custom enclosure, using a brim cutter as an example. However, the principles and techniques discussed here apply broadly to any custom storage or protective solution.

The primary objective of this tutorial is to explore how to precisely measure unusual objects, choose the optimal materials, incorporate hinges and locking mechanisms, assemble multi-part prints, and iterate designs for optimal performance. This guide also covers techniques for printing larger cases on smaller printers and strategies for reinforcing and enhancing durability

1. Conceptualization & Design Planning

Defining the Purpose and Scope

Before diving into 3D modeling and printing, it is essential to establish the specific goals of the case:

● Primary Function: Will the case solely store a brim cutter, or will it accommodate additional tools?

● Design Constraints: Consider whether the case must fit within a toolbox, attach to a workstation, or be portable.

● Usability Factors: Should the case feature a carrying handle, stackable design, or mounting points?

● Environmental Considerations: Will the case be subjected to heat, moisture, or impacts? This affects material choice and design durability.

● Ergonomics & Handling: Evaluate the ease of opening, closing, and securing tools within the case.

Requirements & Preliminary Measurements

● Dimensional Accuracy: Use precise measuring tools to document the dimensions and contours of the tool(s) the case will house.

● Internal Layout Planning: Sketch a layout that ensures an efficient and snug fit.

● Additional Features: Consider foam inserts, ventilation slots, cable pass-throughs, or accessory compartments.

2. Measuring and Capturing Complex Shapes for CAD

Accurately modeling irregular objects is critical for a well-fitting case. The following techniques can be used:

Step-by-Step Measurement and Digitization

1. Use Calipers for Precision: Measure linear dimensions with digital calipers to ensure accuracy down to fractions of a millimeter.

2. Flexible Tape for Contoured Surfaces: For curved or irregular objects, a flexible measuring tape provides better adaptability.

3. Photogrammetry & 3D Scanning: Capture detailed surface data using a smartphone photogrammetry app or a handheld 3D scanner.

4. Tracing for Flat Surfaces: Place the object on graph paper and manually trace an outline, which can then be scanned and imported into a CAD program.

5. Importing to CAD Software: Convert scan data or manually enter measurements into software such as Fusion 360, SolidWorks, or FreeCAD.

6. Reference Points and Alignment: Establish key markers that ensure proper orientation and assembly accuracy in the final print.

7. Test Fit with Prototype Sections: Before printing the full case, fabricate a small-scale test model or a cut section to validate fit and tolerances.

3. CAD Modeling and Software Tools

Recommended Software for 3D Modeling

● Fusion 360 (Parametric precision modeling, simulation, and component-based design)

● SolidWorks (Professional-grade engineering software for mechanical parts and assemblies)

● TinkerCAD (Beginner-friendly but limited in advanced parametric design features)

● FreeCAD (Open-source, parametric, and highly customizable)

● Blender (Best for sculpting organic shapes, though not ideal for precise engineering applications)

Essential CAD Features for Case Design

● Parametric Design: Enables precise adjustments without redrawing the entire model.

● Boolean Operations: Useful for cutting out tool compartments from the main case body.

● Chamfers & Fillets: Smooth edges to reduce stress concentration and enhance durability.

● Lid and Hinge Integration: Ensure proper fit and motion for secure closure mechanisms.

● Multi-Part Assembly: Design split sections that can be joined post-printing.

4. Material Selection for Strength and Functionality

Kingroon Marble PLA Filament

Best Filaments for Custom Cases

Assembly and Post-Processing Steps

1. Surface Finishing: Sanding and acetone vapor smoothing for professional aesthetics.

2. Fastening Methods: Use snap-fit joints, threaded inserts, screws, or magnets for modular assembly.

3. Protective Coatings: Apply sealants for moisture resistance or reinforcement coatings for added strength.

4. Final Fit Testing: Assemble and check for tolerances, hinge mobility, and secure closure.

5. Printing Large Cases on Small Printers

Kingroon KP3S V1

Strategies for Multi-Part Printing

● Segment the Model: Use CAD tools to divide the case into smaller printable sections.

● Alignment Features: Integrate dowel holes, dovetail joints, or embedded nuts for precise reassembly.

● Strong Bonding Techniques: Secure parts using industrial adhesives, mechanical fasteners, or solvent welding.

● Minimizing Warping: Adjust print orientation and cooling settings to maintain dimensional accuracy.

Advantages of Modular Printing

● Scalability: Allows printing of larger enclosures on compact 3D printers.

● Customizability: Interchangeable sections enable future modifications or upgrades.

● Failure Mitigation: If a section fails, only that part needs reprinting, saving time and material.

Final Refinements and Iterations

1. Functional Prototyping: Test printed prototypes in real-world scenarios.

2. Performance Adjustments: Modify weak points and optimize hinge or latch functions.

3. Iterative Refinements: Utilize feedback to improve design for future prints.

4. Aesthetic Enhancements: Incorporate branding, ergonomic grips, or textured surfaces.

Customization & Aesthetic Enhancements

1. Personalized Engravings and Logos

One of the key benefits of 3D printing is the ability to add custom details such as engravings, logos, and textures. This can be achieved using:

● Embossed or Debossed Text & Logos: Designed directly in CAD software by adding or subtracting material from the case surface.

● Texture Mapping: Applying patterns such as carbon fiber weaves, leather textures, or custom designs to improve grip and aesthetics.

● Multi-Material Printing: Using dual-extrusion printers to incorporate different colors or materials in a single print.

2. Custom Color Schemes & Multi-Material Printing

● Filament Selection: Choosing colors that match your brand, personal style, or specific themes.

● Painting & Post-Processing: Using acrylic paints, spray paints, or hydro-dipping to create unique finishes.

● Material Combinations: Mixing flexible (TPU) and rigid (PLA/PETG) materials for ergonomic enhancements and durability.

3. Post-Processing Techniques

● Sanding & Polishing: Achieving a smooth finish using progressively finer sandpaper and polishing compounds.

● Vapor Smoothing: Using acetone for ABS or other solvents to create a glossy, professional look.

● Protective Coatings: Applying polyurethane, epoxy, or clear coat finishes for enhanced durability and a refined appearance.

Waterproofing & Environmental Resistance

GE Advanced Silicone Caulk for Window & Door

1. Sealing Techniques for Waterproofing

● Gaskets & O-Rings: Designing compartments to hold silicone gaskets or rubber O-rings for a watertight seal.

● Epoxy Coating: Applying a thin layer of epoxy to seal porous materials and prevent water ingress.

● Tight-Fit Snap Joints: Creating interlocking mechanisms with precise tolerances to prevent gaps.

2. Best Materials for Outdoor & Harsh Environments

● PETG: Naturally water-resistant and UV-resistant, ideal for outdoor enclosures.

● ABS: Resistant to heat and mechanical stress, but requires post-processing for better water resistance.

● ASA: Superior UV resistance compared to ABS, making it ideal for prolonged outdoor exposure.

● TPU/Nylon: Flexible and durable, capable of withstanding high humidity and extreme conditions.

3. Designing for Environmental Durability

● Drainage Holes: If full waterproofing is not required, small drainage holes can prevent condensation buildup inside enclosures.

● Reinforced Walls: Increasing thickness or using honeycomb infill structures to add strength without excessive weight.

● UV Protection: Applying UV-resistant coatings or using UV-stable materials to prevent sun damage.

● Chemical Resistance: Choosing materials like Polypropylene (PP) or Nylon for environments exposed to oils, fuels, or chemicals.

Shock Absorption & Protective Features

1. Integrating Shock Absorption

● Internal Padding: Adding foam inserts or TPU linings to cushion delicate components.

● Flexible Material Sections: Using TPU or rubberized materials at impact points to absorb shocks.

● Floating Mounts: Designing mounts that suspend internal components with vibration-dampening features.

2. Reinforced Structures for Impact Resistance

● Honeycomb & Gyroid Infill: Using specialized infill patterns to dissipate impact forces while maintaining lightweight properties.

● Double-Walled Design: Increasing wall thickness or creating multi-layer shells to absorb impacts.

● Ribbing & Bracing: Incorporating structural ribs or braces to reinforce high-stress areas.

3. Protective Coatings & Enhancements

● Rubberized Coatings: Applying rubber sprays or TPU overlays for added grip and shock absorption.

● Shock-Resistant Filaments: Using impact-resistant materials like Polycarbonate (PC) or reinforced PETG.

● Corner Protection: Adding rounded or thickened edges to minimize damage from drops.