Versatile Power Supply Cover/Enclosure

Overview:

This is a power supply cover/enclosure to contain the wiring, electronics, and input/output connectors for a 12V AC to DC power supply. It allows me to safely convert electricity from the wall (120v) to 12v DC power for all of my projects. The general concept was to create an enclosure for the power supply which includes mounts for an input power socket, as well as a DC barrel jack and an XT60 connector for DC 12V output. I was inspired by this "Mini Lab Bench Power Supply" as well as these various "Power Supply Covers" on Thingiverse.

Parts:

• 12V 10A AC/DC power supply
  (the 3D printed part could probably be customized to fit other power supplies as well)
• Male power socket (for input from wall) with switch and fuse
• 14 AWG (gauge) electrical wire
• DC power jack (female)
• XT60 connectors (female)
• 3 pin power cord
• 2x M4 (~10mm) screws (for mounting power socket)

6x M3 screws (for mounting power supply to enclosure) ### Assembly:

1. Solder wires to the AC power socket, DC power jack, and XT60 connector. The AC power socket should be wired according to these instructions.
2. Insert the three sockets into the 3D printed case and (optionally) glue/screw in place.
3. Keeping the wires from the connectors as short as possible, attach them to the screw terminals on the power supply. Using the symbols from the power supply as a reference, the "ground," "neutral," and "hot" wires from the AC power socket should connect to "earth," "neutral," and "load" respectively on the power supply. The DC output ports should attach to +V and -V with the correct polarity.
4. Slide the power supply into the case (the wires will be squeezed into the remaining area).
5. Secure with M3 screws on the back and side.

Print Settings

Rafts:

Doesn't Matter

Supports: 

Yes

Resolution:

0.2 - 0.3mm

Infill: 

25%

Filament:

PLA 

Notes: 

Print time - 12 hours

Print with the tall wall/backing vertically positioned (perpendicular to the build plate). This compromises the strength of the back but allows for fewer supports. The input and output sockets should face to the side, and the bottom of the enclosure should sit on the build plate.

Print at 102% size so that everything fits!

Change Log

9/10/2019

Initial design/concept.

9/28/2019

Refinements to how the power supply is secured, adjustments to screw hole placing, improved strength of rear support/backing, adjusted power socket holes and placement, refined accessibility to the LED status light and potentiometer (for voltage adjustment), and improved esthetics.

9/20/2021

Added the .f3d source file if users want to customize the design.

Category: Electronics