UPDATE

Version 2 - January 3rd, 2024

Added user editable parameter to increase the thickness which holds in the bolt. Increasing this value should be a simple way to improve the strength of your hinges. This is not completely tested, so let me know if you run into problems. Thanks to user @tehgrn for requesting this change.

Waterproof Rugged Box

This is not "yet another" rugged case. This is a truly parameterized version in OpenSCAD compatible with the Thingiverse Customizer. The design requires minimal external parts (either M3x25mm or 4-40x1in. bolts) to create a truly waterproof box. The switch to OpenSCAD makes it much more accessible to remixes, as the design will import directly to other programs like FreeCAD.

The Gasket

Rather than require a printed gasket, I designed this for compatibility with 2.85mm filament. For all of the examples I show here, I used blue flex TPU (3D Universe TPU 2.85MM BLUE) to seal the enclosure. You can print a gasket if you want, and it will be easy to create one from the code. But...

This means that the design is compatible with Bowden tube style printers!!!

Submersion Test

I did a submersion test on my boxes until I was satisfied with the "bite" of the gasket by the lower clamshell. Each test box was submerged 10" in water for 10 minutes with a slip of paper inside, with 3 repetitions. The edge I chose is pictured as a white case with a slip of paper which reads "Test 4". The paper in the picture shows the amount of water ingress on the wet paper from this test, very little. My gasket using 2.85mm filament will never be perfect due to the required cut in the filament, but I am satisfied with this result. It's not quite IP67 so I am classifying this as only IP65, but I challenge you to beat that with your own print.

Rugged Tests

I actually designed this in August 2022, but I am only posting it now, nearly a year later. I used that time to abuse the heck out of the test cases pictured here. They held up quite well, including during field work. The print settings here reflect the toughness that I put into the prints, but there is wiggle room if you are using this in a less-rugged environment.

Mouse Carrying Case

The burgundy colored case in my pictures is a modified version of this print to carry a wireless mouse and batteries. This example demonstrates what is possible using the OpenSCAD design beyond the Thingiverse Customizer. Included in this design is an option to play with the subtraction "inserts" which define the shape of the container. I have left my commented code which was used to design the mouse.

Writing Utensil Case

I included stl files for another example which used FreeCAD. For this design, I imported the OpenSCAD design into FreeCAD and edited it for a 2-color text design. The result worked, but the clasps stick out a bit. I don't recommend making a design this thin, but it will not throw an error. I used foam insulation to line the box so I could quietly carry around a box of pencils and pens in the enclosure. This design serves to show the options available beyond the OpenSCAD file itself.

License Note

This project is not for profit and cannot be used to make you money, but it is not "share alike", so feel free to modify it to suit your needs. I encourage you to donate to my paypal if you get something out of this though. If you use this for a scientific application, and you need a DOI to cite, hit me up.

Why did I make this?

As much as I love the original design that zx82net put together for a waterproof box similar to pelican cases, I really don't like Fusion. I wanted a truly "open" version, so I completely redesigned it from scratch in OpenSCAD. I no longer design in Fusion since the license change and I don't really have a capable Windows computer anymore.