Housing for In-Line Rocker Switch

Fits a snap-in type rocker switch. Features built-in strain reliefs.
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updated December 7, 2023

Description

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I designed this in order to add a toggle switch to a small external DC power supply, in-line from the output side. The two halves fit together very nicely, and it feels surprisingly solid even before adding the screws.

Fits any snap-in type switch measuring approximately 12.5mm × 20mm, such as a C&K D-series or MARQUARDT R30.

The input and output holes with strain reliefs will accommodate a typical, thin gauge, two-conductor wire, measuring up to approximately 6mm × 2mm.

The model for the bottom half includes cross-supports for the screw holes, which should pop out without difficulty.

The following should go without saying, but I'll say it anyway. 

!!! THIS IS TO BE USED FOR LOW-VOLTAGE APPLICATIONS ONLY !!! 
!!! DON'T ELECTROCUTE YOURSELF !!!

 

PRINT SETTINGS:

  • Supports required: NO
  • Material: PLA or PETG
  • Nozzle: 0.4mm
  • Layer height: 0.15mm
  • Perimeters: 2
  • Infill: 20%

ASSEMBLY INSTRUCTIONS:

  1. After printing, remove the screw hole supports from the bottom half by gently pressing with a punch tool or small screwdriver from the top side.
    • They should pop out without difficulty. If they don't, your filament may have been running too hot and/or too wet. They should still come out with enough pressure. Just try not to stab yourself when they finally break away.
  2. Use an M2 screw to pre-thread the holes on the top half prior to assembly.
  3. Run your wires through the underside of the snap-in hole and solder to your switch prior to actually snapping it in.
    • It's a fairly tight fit, so you may need to make a side-on approach, rather than soldering them straight out. Fit everything together first, and you'll see what I mean.
  4. Finally, press the bottom half into place and assemble using four M2×5 or M2×6 screws. 

Good luck!

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