WIP - Bus Pirate milled case

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Re: WIP - Bus Pirate milled case

Postby ian » Wed Sep 07, 2011 12:04 pm

It looks like it is easy to get a quote from protomold online with your files:
https://uploads.protolabs.com/protomold ... Email.aspx

They also give free or reduced parts to worth people (us?):
http://www.protolabs.com/CoolIdea.aspx

If you upload the standard file, Seeed can also get a quote in china. DP doesn't take profit on accessories, so the actual cost could be the retail cost (plus your royalty).

v4 is the same size as v3.5, they were designed to fit a cheap case Seeed could find. Only the header size (maybe LED location?) is different.
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Re: WIP - Bus Pirate milled case

Postby fcobcn » Wed Sep 07, 2011 5:43 pm

Today I received the lightpipe that Menno recommended, it fitted perfectly on the last prototype.
You can clearly see the state of the LEDs from a good distance.
I also milled the top engraving, it looks nice, but something much better can be designed.

bp_case 1.png


Here are the STL files of both halfs, please consider them alpha.

BP_case.zip
alpha version
(31.47 KiB) Downloaded 376 times


I would like to try to fit the new 3mm magnets I ordered in the PCB holes, to lock the case and the PCB tighter than now.
Also, like bearmos said, I need to add drafts for plastic injecting, it shouldn't be a problem in CAD design, but I need to do some research on it.
Ian, please PM me an address to send you the last prototype I have made.
If were are going to mass produce, user feedback is fundamental.
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Re: WIP - Bus Pirate milled case

Postby ian » Thu Sep 08, 2011 1:09 am

It looks killer!
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Re: WIP - Bus Pirate milled case

Postby fcobcn » Fri Sep 09, 2011 7:29 am

ian wrote:It looks killer!

Thanks Ian! The latest prototype is on the way to you.
I have just received the new magnets I was waiting for, they are much stronger than the previous ones.
Here are some pics of the new versus the old ones.

bp_case 1.png


I will try to move the magnets from the corners of the case to the PCB holes, as they fit perfectly:

bp_case 2.png


Looks like this will be a milling weekend!
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Re: WIP - Bus Pirate milled case

Postby sqkybeaver » Fri Sep 09, 2011 8:41 am

this is turning out amazing!
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Re: WIP - Bus Pirate milled case

Postby Menno » Fri Sep 09, 2011 1:29 pm

fcobcn wrote:
I'm still looking how to fill the circles next to each pin name with a different color, a not water soluble material, and cheap! So any cable coding could be labeled on the case.


Have a look at Revell modelling paint or simular. It's available in all kinds of colors. Don't know about cheap and availability in the US though.
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Re: WIP - Bus Pirate milled case

Postby fcobcn » Fri Sep 09, 2011 3:27 pm

Menno wrote:
fcobcn wrote:
I'm still looking how to fill the circles next to each pin name with a different color, a not water soluble material, and cheap! So any cable coding could be labeled on the case.


Have a look at Revell modelling paint or simular. It's available in all kinds of colors. Don't know about cheap and availability in the US though.


Fantastic!! I think this is it, once again Menno!
I'm in Barcelona, so probably I can find it here.

Here's a pic of how the bottom graphic looks like,
Next version will also include the dots for coloring, and the rest of the pins that I have omitted.
You will be able to find all the info in one go.
Also missing is a url to DP.

bp_case 1 (1).png


It would be great if someone with a reprap tries to print the STL files.
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Re: WIP - Bus Pirate milled case

Postby CapacitiveMind » Fri Sep 09, 2011 8:55 pm

fcobcn wrote:It would be great if someone with a reprap tries to print the STL files.


The case is printing now. The STL files look great. I will post photos when they are done.
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Re: WIP - Bus Pirate milled case

Postby CapacitiveMind » Fri Sep 09, 2011 11:49 pm

First Print is complete.

A bit more post processing would make for a very nice case.

I don't have a Bus Pirate to show the fit of the board, but the case design prints very easily.

I'll have the post the pictures in a few hours to meet the board requirements.
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Re: WIP - Bus Pirate milled case

Postby ian » Sat Sep 10, 2011 12:25 am

@CapacitiveMind - welcome to the forum. I'm sorry about the spam filter.
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Re: WIP - Bus Pirate milled case

Postby fcobcn » Sat Sep 10, 2011 12:45 am

CapacitiveMind wrote:First Print is complete.

A bit more post processing would make for a very nice case.

I don't have a Bus Pirate to show the fit of the board, but the case design prints very easily.

I'll have the post the pictures in a few hours to meet the board requirements.


Wow, that was fast, thank you CapacitiveMind!
Can't wait to see how it looks!
When designing the case, I had in mind the option of reprap printing, the only thing that's currently not possible to print are the graphics.
Too bad that you don't have a BP to try it out, you should definitely get one, it's a very handy tool ;)
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Re: WIP - Bus Pirate milled case

Postby CapacitiveMind » Sat Sep 10, 2011 10:00 pm

ian wrote:@CapacitiveMind - welcome to the forum. I'm sorry about the spam filter.


Thanks ian.

Without the filter, we'd all be overrun.

Total print time was around 90 minutes.

Image

Image
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Re: WIP - Bus Pirate milled case

Postby fcobcn » Sun Sep 11, 2011 5:31 pm

It looks really good!
90 minutes is the same time that takes me to mill both parts (not including the graphics).
I have to find the time (and the money) to finish that old bitsfrombytes darwin machine that I have gathering dust.
I need a compatible extruder, the one that came with it was crap.

I did another prototype during the weekend, this time using the 3 mm magnets in the same position as before, now I'm happy with the holding force.
New versions of the graphics are ready.
Also ordered the paint that Menno recommended, so a fully complete prototype should be ready in about a week.

Yesterday I uploaded the files to protomold to get an idea of the prices. Let's hope to get an answer tomorrow.
Ian, did you had any luck with seeed studio?
If you need another 3D format, just drop me a line.
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Re: WIP - Bus Pirate milled case

Postby ian » Mon Sep 12, 2011 1:55 am

I asked seeed, but they thought it was really expensive to have it done locally and suggested I get a protomold quote for reference first. I signed up and tried to upload the files, but they wanted a different format. It's on my list to ask for different files this morning, but it looks like you beat me to the quote anyways ;) I also wrote up everything for the 'gimme free mold' deal, I think we might have a chance at that b/c of the blog, open hardware, bla bla bla.
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Re: WIP - Bus Pirate milled case

Postby fcobcn » Tue Sep 20, 2011 8:57 am

Quick update,
Here's the latest version with painted engravings. I think it looks nicer without them, but it's much easier to read the text.
If I do another prototype, I will probably paint just the dots.
I have been doing research about the plastic injection process, there are a couple of problems for this design.
But it's possible to adapt it without loosing the look & feel.

bp_case 1.png


bp_case 3.png


bp_case 2.png
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