Premium Protective Housing for DJ Control Mix

I come from a family of musicians, and I know how much pride my family takes in their instruments and gear. Usually they come with metal casing filled with foam padding, and that was my idea here.

I made my design in such a way that you can print it fully on your 3D printer without anything additional and have a great case, or you can do a bit more and have a premium one.

Why do I say great and premium, simply because with using only 3D you won't use full potential of this protective case.

Okay, lets cut to the chase!

For premium case you will need:

•  12 Rectangular Neodymium Magnets (40x10x5mm)
•  2pcs 390x150x50mm of black foam padding  or EVA foam for main body
•  1pc 390x150x25mm of black foam padding or EVA foam for cover
•  Generic 3D printed or metal hinge

In main body and in cover there are cutouts on front, left and right side for magnets. You need to pause your print before layer that covers cutouts for magnets. There is around 0.25mm tolerance on each side for magnet so I suggest you drop a tiny bit of glue in hole before you place your magnets. After you placed all of your magnets resume your print. Make sure not to mix polarities, otherwise you won't be able to close lid.

Now for foam padding you can use black foam padding or EVA foam or if you have something else that think it can work feel free to use but note that you will need 2 pieces of 5cm thickness and 1 piece of 2.5cm. I've designed holes in foam so that every part mostly stays flush with top of the foam, and they all have tolerances 0.4 - 0.6mm in width and 1mm up and down. So in order to make full use of design you will need a flatbed CNC and you can generate gcode from stl that I provided or you can simply use EVA foam and CO2 laser and just cut holes. Holes in foam are made to accomodate parts:

• Knob remover by Hercules
• Headphone stand by Hercules
• Replacement knobs and faders by Hercules
• Desktop phone holder by me
• Generic compartment
• Hercules DJ Control Mix

And for the last part, you can use hinges if you like. As I said magnets are placed at front and sides, and they will hold lid close but if you want you can add a hinge on the back side so you dont lose lid. Before you install hinge I would suggest you place something to create a small gap between lid and body (2 credit cards on each side) and then you screw in your hinge. That way you won't have problems opening and closing it.

Design is made in one piece, and because most slicers have great cutting abilities I didn't see a reason to make it 2 part. But if neccessary I will make it 2 part with easy assembly.
 

Unfortunately I can't print a sample, my printer died on me, but as soon as I get it up and running again I will post some pictures.