Customised Junction Box Cover — parametric, no base, cable entries, corner bosses

A minimalist lid-style enclosure designed to cover a bundle of connected wires and protect the junction from dust and accidental contact. No base — the cover sits open-side-down over the wires and is screwed directly into a wooden surface through the four corner bosses (self-tapping screws, no threaded inserts needed).

Key dimensions (all parametric in the SCAD file):

• External: 55 × 95 × 28 mm

• Wall thickness: 2 mm everywhere

• Corner bosses: Ø8 mm outer, Ø4 mm through-hole, full height

• Cable entries: Ø8 mm, centred on both short walls, U-profile (semicircular arch + straight sides to open edge) — cables slide in from below

Countersinks: not printed. The corner holes are plain Ø4 mm. Countersinks for flush (flat-head) screws are not needed — the bosses are designed for pan-head or bugle-head self-tappers driven straight into wood. If you want countersinks for countersunk screws, drill them by hand in 30 seconds.

A note on OpenSCAD: the model generates a non-manifold warning during render (F6). This is caused by tangent geometry at the cable entry — the cylinder and rectangle meet at a shared edge. In practice: the STL exports cleanly (F7), loads without issues in PrusaSlicer / Bambu Studio, and prints perfectly. Slicers auto-repair the geometry silently.

Print settings:

• Orientation: closed face (top plate) DOWN on bed, open side UP — no supports needed

• Material: PETG or ABS

• Walls: 4+ perimeters | Infill: 30%+

• The red stripe visible in the photos is a leftover strip of red filament on the bed — consider it a personal hallmark or maker’s monogram. ))))