Design notes on development of v1 Alpha Housings

Added by J. Simmons 11 months ago

This post will be my running notebook of work to desig prototype housings for the v1 Holoseat Alpha.


Replies (6)

RE: Design notes on development of Sensor Housing - Added by J. Simmons 11 months ago

Initial research

Some quick conclusions

  • Looking to create a transition fit for the two parts of the sensor housing
  • Going to start with the i.materialize min wall thickness (1mm) and min clearance (0.3mm in narrative vs design specs table)
  • Going to start with a base thickness of 2mm for added structure
  • If needed, will increase thicknesses in 0.5mm steps
  • Plan to print with my standard settings (may switch to 100% fill)

RE: Design notes on development of Sensor Housing - Added by J. Simmons 11 months ago

After taking some initial measurements, going to use 1.5mm wall thicknesses to match dimensions related to the jack.

RE: Design notes on development of Sensor Housing - Added by J. Simmons 11 months ago

Board dimensions = 12.8mm x 17.8mm
Total clearance = 0.3mm
Wall thickness = 1.5mm * 2 = 3mm
Total outer dimensions for box around board = 16.1mm x 21.1mm
Total inner dimensions for box around board = 13.1mm x 18.1mm

RE: Design notes on development of Sensor Housing - Added by J. Simmons 11 months ago

Clearance for upper half = 1mm

Finished first revision last night. Still to do:

  1. consider reducing upper half clearance
  2. determine required height to align with tone ring when mounted on pedals
  3. document printer/slicer settings (first in this thread)
  4. publish cad files

RE: Design notes on development of v1 Alpha Housings - Added by J. Simmons 10 months ago

Some helpful tutorials on modeling snapfit cases in Fusion 360

Square Cases

Round Cases

(1-6/6)