Le Sensor Puck - Boîte à projets ESP8266 & ESP32

I build a lot of ESP-based sensors for Home Assistant related projects and was struggling to find a project box that could be used with multiple sizes of ESP board and also didn't just look like a 'box'. The Sensor Puck started off as a single-board design 3 or 4 years ago and has gone through many iterations to become what it is today. It's now compatible with every ESP board I've got access to, has multiple methods of adding sensors (both internal and external) and has completely tool-less assembly. It can even be used to build an LED desk lamp! It's now the only enclosure I use for ESP-based sensor projects.

Features:

The ESP boards are held in the base using compliant spring clamps with stepped faces, allowing the clamps to accept a wide variety of board widths. While the clamping force is quite reasonable, if you wish to insert a USB cable once the case is assembled, I would suggest adding some hot glue to the edges of the board. Multiple base heights are included depending on the space you need. Two styles of top are included. One has a grid of sockets that can accept sensor mounting pins and plates. The pins are 3mm and will push through most sensor boards for attaching directly to the socket grid. Sensor boards can also be attached to the 2x2 grid plates using hot glue or double-sided sticky pads. There is also a full plate that can be customised to your needs. An example is included for a speaker, microphone and amplifier board. The other style of top is completely plain. This is intended for projects such as motion sensors, where you can simply punch a suitably sized hole through the front by using a modifier in your slicer. Again, multiple heights of top are included. The top and bottom sections are keyed for orientation and are connected using spring clips which are supplied in 3 different sizes. A spacer ring with a 3mm cable tie socket (for strain relief) can be added between the top and bottom sections for external cable access (for things like probe temperature sensors etc). I've also included another spacer ring and LED lighting top that can be used with a 165mm length of 10mm wide LED strip to build a small desk lamp.

QR Mount

Also included are base files of my quick release, multi-position sensor mounting system so you can build an adjustable, free-standing or wall-mounted sensor. Versions of the base components are included with the circular cutout required for the QR screw component.

STEP Files

I have included STEP files for the basic design components: Top (plain and with socket grid), Bottom, full sensor plate and 2x2 sensor plate. You can use these in most CAD packages for further customisation.

Pricing

A lot of work has gone into producing this design, making it as flexible and expandable as possible. I've set a very minimal amount on the purchase of these files. The pricing has been left open so if you want to show further appreciation, it would be gratefully received.

Usage

These files have been made available for personal projects only. Distribution of the files, and any commercial use, including but not limited to selling of prints, modifications, etc., is strictly prohibited.

#CULTSXBOX

Parts required:
For each top and bottom, you will need 2 Board Spring Clamps and 2 er Clips. The standard er clip is OK for most combinations. If you are adding a cable ring, you will probably need the long clip. If using 13.8mm top and 8.6mm together, you will need the short ers.

For the QR mount you need to print 2x Mount Lock Nuts, 2x Mount Screws, 1x Mount Arm and the round base plate.
2 x M3 Cap Head machine screws (20mm) and nuts are required to assemble.

All parts are in their intended print orientation.

PETG is recommended for the board spring clamps and the er clips. The spring clamps will work fine in PLA but tend to '' their compressed position. PETG springs back a lot better.

Print settings for the puck components:
0.2 Layer Height
3 outer walls
5 top and bottom layers.
Infill 10% (but doesn't really matter as there will be minimal infill).
No s required and, if printing the cable access ring, they should be disabled (the cable tie channel will end up being blocked by s).

Print settings for the QR mount locking ring and mount screw:
As above but use 0.12 layer height in order to print the threads. You may also need to reduce your print speed to below 100mm/s