Replacement Case for Tousek BT40-2B Remote Control

The Tousek remote control BT40 does not have a good haptical feedback. The button plates are quite soft and tends to get broken especially by users having longer fingernails.

I had a worn out case not being reliable anymore. But electronics still works fine. So I designed a replacement for the case.

The case has been designed to be competly closed and as small as possible.

Printing

For reliable function, base and cover have to printed differently:

Base

Base plate has fragile snappers for fixing the PCBA. Layer height should be optimized for best layer adhesion (0.15 or 0.20mm for 0.4m nozzle).

• Filament: PETG

• Nozzle size: max. 0.4 mm

• Layer height: 0.15 mm

• Infill: 100%

• Support: not needed

Cover

The cover plate has to be flexible to enable pressing the button below. To get a flexible but also robust membrane for pressing down the buttons, layers should be quite thin (0.1mm) and ironing should be used.

• Filament: PETG

• Nozzle size: max. 0.4 mm

• Layer height: 0.1 mm

• Infill: 100%

• Ironing: on

• Support: not needed

Assembly

Additionally to the filament for base and cover you need

• 4x tap screw 2.2 x 6.5 mm

• 11mm transparent filament 1.6mm

Put the transparent filament into the hole and fixate it with some glue if necessary.
Press the PCBA into the fixations in the base (be careful not to break the snappers).
Add the battery.
Close the case and tighten the 4 screws on the back side.

Have fun!