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I wanted a little case for one of my XAIO boards and a variety of mounting options as I have a few sitting about so I can use them in different ways. Later I realised I could modify it to fit the other XAIO models.

If you are looking for something fun to do with your device and it is ESP32 based, have a go at setting it up with Home Assistant via ESPHome and plugging in and configuring some supported sensors, more information can be found in this guide. Sorry I am not able to support you with ESPHome or electronics :)

Currently there is a simple base, a wall mount base and an 8x2mm magnetic disc mount option available, we will be at least adding a magnetic base in the short term and possibly a stand.

Required For Assembly

• 8x M2 inserts, CNC Kitchen/Ruthex/others of similar size

• 4x M2x8 screws, for the lid

• 4x washers, for the lid

• 4x M2x12 screws for the main body/base

• Pin strip

• Soldering iron

• Grove Base

• Seeed XAIO ESP32S3 Sense/RP2040/SAMD21/nRF52840/ESP32C3/nRF52840 Sense

For the optional magnetic mount you will need 1-3 8x2mm disc magnets. Probably a good idea to use three if you are plugging in accessories and use some glue to ensure they stay in place.

Printing

There is a pre-configured Bambu file available with colours matching the above pictures as well as an un-configured 3MF.

Use the “sense” objects of the lid and the main body if you have the ESP32S3 Sense, else use the “others” objects along with the base of your choosing. 

The pre-configured Bambu file has the the base and lid options on the first plate. The second plate has the main body options. Delete the optional parts you do not want to use.

If you are configuring the print yourself it is an easy print with a 0.4 nozzle. The main body needs hybrid tree supports to support the tray and SD card/switch/USB-C port holes for the “sense” variant. I printed the above at 0.16 layer height so it came out smooth.

Post

It is sometimes the case that there is a small mess under the tray where the supports were. Take a sharp, thin knife and make it tidy to prevent issues with the SD card slot.

Assembly

	First, get out your soldering iron and solder pin strip into the holes at the side of the Seeed XAIO unit. Following this, plug the soldered unit into the Grove base. If you are using a device with a camera, remove the camera unit if it is attached. If you are using a device with an antenna, connect the antenna.
Install 4x M2 inserts into the four holes that protrude from the sides of the main body.
Install 4x M2 inserts into the four holes in the base.
If you are using the optional screw mount base, mount it to its final location after the inserts have cooled.
If you are using the optional magnetic mount base put a tiny dab of glue in the holes and poke in the magnets.
If you are using a device with an antenna, thread the antenna through the massive hole. ensure the cable is placed so that it goes up through the thin section and rests at the side.
Carefully insert the boards into place. Being careful aligning the USB port and switch is the key to success. Keep the cable antenna in place so it is aligned with the gap in the side if one is present.
Align the main body on top of the base, you will need to fold the antenna if you have one to make it fit well. Screw M2x12 screws in the 4 holes here. Careful to not damage the MCU or base board. We do not use washers for these screws, so be careful not to connect them too tightly.
If using a device with a camera, connect the camera to the board and insert it into the upper tray. Ensure it is pushed up fully into the upper tray.
Connect the lid with four M2x8 screws and washers. If you are using a device without a camera be sure to use the lid without a hole. Congratulations, you are done!

Versions

2024012701: Enlarge USB-C port hole to manage different pin strip offsets.

2024012301: Initial version.

ESPHome

Here is a working config file for ESPHome for the command line utility for the XAIO ESP32S3 Sense board, which is the one I initially posted here. Note that you need to enter your own wi-fi details, and depending on how you want to orient the device you may need to change the “vertical_flip” and “horizontal_mirror” settings.

Sorry you will need to work out ESPHome things by yourself but I wish you the best of luck :)

# Configuration for ESPHome
esphome:
 # Name of the ESP32-S3 device
 name: xsense1
PlatformIO build options
 platformio_options:
   build_flags: -DBOARD_HAS_PSRAM
   board_build.arduino.memory_type: qio_opi
   board_build.f_flash: 80000000L
   board_build.flash_mode: qio
Configuration for ESP32
esp32:
 board: esp32-s3-devkitc-1
 framework:
   type: arduino
Enable logging
logger:
Enable Home Assistant API
api:
Over-the-Air update configuration
ota:
Wi-Fi configuration
wifi:
 ssid: "Your Wifi SSID"
 password: "Your Wifi password"
Enable fallback hotspot (captive portal) in case wifi connection fails
 ap:
   ssid: "Xiao-Esp32s3 Fallback Hotspot"
   password: "MoLTqZUvHwWI"
Captive portal configuration
captive_portal:
Configuration for the ESP32 Camera
esp32_camera:
 id: espcam
 name: My Camera
 external_clock:
   pin: GPIO10
   frequency: 20MHz
 i2c_pins:
   sda: GPIO40
   scl: GPIO39
 data_pins: [GPIO15, GPIO17, GPIO18, GPIO16, GPIO14, GPIO12, GPIO11, GPIO48]
 vsync_pin: GPIO38
 href_pin: GPIO47
 pixel_clock_pin: GPIO13
 resolution: 800x600
 vertical_flip: false
 horizontal_mirror: false
Configuration for the ESP32 Camera Web Server
esp32_camera_web_server:

port: 8080
mode: stream
port: 8081
mode: snapshot

If you like my designs or find them useful it would be great if you can support me by joining my club on Printables for at least a month, which gives you access to various extra models for the duration of membership. Another alternative is to buy me a coffee using the button below. Thank you!

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