DIN Rail Electronics Enclosure

This is an electronics enclosure using widely available DIN rails, giving you versatility to meet your needs.

Please note that the pictures of the finished enclosure are of a previous version, prior to making the mounts flush and using countersunk screws. 

I originally made this to mount under my lack enclosure, but it can be mounted virtually anywhere you have the space and something to screw to.

Internal dimensions are 270x270mm.

It fits a PSU the size of Meanwell-LRS models, and fits a LRS-350 well. In addition to the PSU, the enclosure is housing a rpi 3b+, skr mini e3 v3, tobsun DC-DC, heater bed MOSFET, BTT U2C, DIN-mounted WAGOs.

There are also options available for those who may only need certain features, or if you already have certain parts available.  The small arches on the floor of the enclosure are for zip ties for cable management. 

Unless you have a large bed (~350mm) I don't recommend trying to print this as one piece, simply due to potential for warping and/or failure, leading to a lot of wasted filament. HOWEVER, you will have the benefit of having slightly more internal volume, plus the option for every available panel mount.

When assembled, the enclosure is VERY rigid, especially thanks to the DIN rails and M3 connections where the quarters meet. 

Required Parts-

2x 4010 or 5010 DC fans

You will need the style of rocker switch pictured. It's commonly found, and is the same one used on Enders. Example- https://a.co/d/09ZcB0QU

1 or 2x USB panel mount- the one I used- https://a.co/d/0bT3YzQk

1x HDMI panel mount- the one I used- https://a.co/d/0eHmnVih

6x 4-pin - Molex (with matching pins) Part Number - 0430200400 Must be same type as pictured.

3x 6-pin - Molex (with matching pins) Part Number - 0430200608  Must be same type as pictured. 

Required Hardware-

2x DIN rails, cut roughly 210mm and 260mm in length. I used these aluminum ones that were very easy to cut- https://a.co/d/0cYePMp6

Various length M3 SHCS screws (shouldn't need many or any over 16mm)

~32x M2 self tapping screws for the lid, the DC-DC mount .

6x M2 countersunk screws for micro-fit mounts.

~2-8x M3 countersunk screws- XT60 mounts and/or covers. 

M2/M3/M5 nuts

~14x M5x10/M5x12 BHCS to secure the DIN rails.

I used #2 drywall screws to secure the bracket to the lack, but any coarse-thread screw that fits will do.

6x Voron-spec M3 heatset inserts to firmly secure the bracket to the enclosure. 

Required STLs- There are only variations of 2 quarters of the enclosure: the 4010/5010 fans and the XT60/LM2596 quarters.

 Required additional STLs-

This one if you're using the quick-connects:

This one of you're using the quarter with LM2596

This one if you're using XT60 connectors (if not, use the cover or print the DC-DC mountable Quarter)-

Pictured below are the cable dimensions which the enclosure was designed for. You can find these cables from various sources.

Printing-

*THIS WAS MADE WITH SHRINKAGE COMPENSATION IN MIND. If you print in ASA/ABS without compensation, simply scale the parts up in x/y by 0.05%. PLA/PETG has shrinkage as well but I doubt it's enough to effect anything. 

I printed this in quarters out of ASA on a Voron 2.4 300mm, with no special settings other than tree/hybrid supports (touching build plate only, 40 degree threshold angle). I did not use a brim and had very minor lifting in the corners, which had no effect on function. 

Assembly- 

I recommend assembling in this order: 

1. 4 quarters fitted/screwed together + DIN rails. I used a rubber mallet to fit the dovetails together.

2. Install PSU, power outlet (wire to PSU) and LM2596 mount if applicable (wire to PSU)

3. Install rest of electronics. I recommend not installing the lid until you have all the hardware/software buttoned up, as it can add a lot of wasted time and frustration to the last steps (ask me how I know)