Design notes on development of v1 Alpha Housings

Added by J. Simmons about 1 year 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 about 1 year 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 about 1 year 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 about 1 year 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 about 1 year 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 about 1 year ago

Some helpful tutorials on modeling snapfit cases in Fusion 360

Square Cases

Round Cases

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