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DC Barrel Jack Enclosure (DC022B) with Rocker Switch — image 1
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DC Barrel Jack Enclosure (DC022B) with Rocker Switch

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Enclosure for DC022B power socket and rocker switch. Frontplate mounts with M3 heat inserts.

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Model information

Category
Electronics
License
Creative Commons — Attribution — Noncommercial — Share Alike

Made a compact DC power input enclosure designed around the DC022B (5.5x2.1mm) and KCD1 rocker Switch. I created the box to add an inline power toggle for a 24V LED workbench light.

Before you print:
The rocker switch cutout is modeled precisely at 19.5 x 12.2mm, it's a snug fit.

This box is overall an intentionally tight fit, designed to keep the footprint small. However, there is enough space to fit 3 two slot WAGOs (see pictures), it can be a bit fiddly to work in the small box, I used a screw driver to move the parts in their place.

Layouts:
Version A: DC022B and KCD1 switch both on the front plate - cable input in the back, drill more holes if needed
Version B: DC022B on the Back Plate, KCD1 switch on the front plate - cable input in the back
Version C: DC022B on the Right Side, KCD1 switch on the front plate - cable input on the left or right side

Print Settings:
I've tested PETG (white Part Variant A+C) and PC (Variant B) - with PC you might want some XY off-set, I've used 0.18% (Prusament PC Blend default Profil)
Perimeters: 3 Walls
Infill 100%

Assembly:
I used M3 x 5.7mm heat inserts (outer diameter 4.6mm, designed for a 4mm hole)

M3 screws (4x) you can use 6 to 10mm in length, the internal screw channel is 10.3mm + 2mm (front plate) deep.

Cable Entry is 4mm, if you're using a thicker wire, you can drill the hole out to your required size.
As a strain relief, I just used a zip-tie around the cable on the inside.

The Bottom is flat, I've mounted mine with double sided tape and one screw in the back (Variant C) there are no premade screw holes for the mounting.

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