About a year ago my UPS exploded after the power FETs decided to go short circuit and unsolder themselves from the board. My attempts at repair failed, so I pulled it apart. One thing I was left with was the power distribution panel. It was a clip-in module and I thought maybe I could use it in a project or other. The outlets are too close together to use with power bricks, but it’s ideal for a place in the garage where I’m always plugging in and unplugging tools.
Fast forward to today and I sat down with a set of vernier calipers and Blender and designed a case for it.
First I made a few test models, checking for fit and testing whether the clips would work. The first test piece was pretty close. I did a second print with some slight modifications and a separate print to check the mounting of the strain relief clamp. That done, I extended the test piece down to the correct depth and added mounting geometry. The case is open at the bottom, because I intend to permanently mount it to a surface.
Once I started the print, I collected a cable and stripped the end. I also repositioned some of the interconnecting wires on the distribution panel. Then it was a case of waiting for the print to finish.
4 hours later and the print was completed. I hit it with some hot air to get rid of the fine stringing and then set about installing the wiring. That was as simple as running the cable through the hole, fitting the strain relief clamp and wiring in the power panel. Once that was done, the panel simply clipped into place and the job was done. All I need to do now is mount it where I want to use it.
Thoughts?
I reckon it came out really well. The new Creality printer does a great job where my old MBot Cube printer would have, well, it would have been bad. The hole for the strain relief clamp printed without issue, even though I elected not to use support. The little overhangs for the retaining clips also printed without issue and the resolution was good enough for reliable mechanical connection.
I’m not 100% sure of the strength of the print because I did not increase the infill density, which had been in the back of my mind, but we will see how durable it is in use and if the worst happens, I can reprint the model with greater density. Overall, the project worked really well.
