Portable 2 Gang Outlet Box - TPU Version

Pictures with the strain relief coming soon.  I seem to have run out.

Safety Disclaimer: this project involves working with electricity.  Please make sure you know how to be safe before attempting.  Please also be aware of the flammability/toxicity of the 3D printing materials you use to make these enclosures.  In an ideal world, they'd all be V0 rated self extinguishing materials.

This is the 3rd iteration of my portable outlet box.  I initially tried to replicate some more commercially available items often used in the live event industries, but eventually moved on to a more standard "quad box" design after receiving input from friends in the industry.  The previous version was intended to be printed in PETG/ABS/ASA, but those proved to be too brittle.  A drop on the floor would often cause the corners to shatter. 

This revision adjusts the thickness of some of the walls to be more compatible with TPU.  Print in a hard TPU - minimum I've had success with is 95A, but I prefer the results from Sainsmart's TPU 64D.  I'm hoping to try some even harder options in the near future.  The harder the TPU used, the fewer perimeters you need to maintain stiffness, and therefore lower cost/print time.  The face plate should still be printed in PETG/ABS/ASA.

There are two options available; one that takes a 3/4" NPT strain relief, and one that takes a Neutrik/Seetronic True1 Appliance Connector.  I might come back and add options for PowerCON or single True1 connectors if there's interest.  EDIT: These files are now available.  PowerCON passthrough, True1 passthrough, and single D Series.  I've also added STEP files with no holes so you can add any inlet/outlet connectors you like.

I was also requested a single gang version, which is available as a STEP file.  I haven't bothered to make different varieties, as these are really difficult to work in - there's not really enough room to comfortable wire anything up.  But it is available if someone finds it useful.

Parts needed:

Duplex Receptacle (Outlet): Home Depot
Outlet Top/Bottom Mounting Screws: McMaster
Outlet Center Mounting Screws: McMaster
True1 Mounting Screws: McMaster
Strain Relief: Mouser (3d printable install tool available here)
OR
True1 Appliance Connector: Mouser (Neutrik) or Thomann (Seetronic) or Alibaba

Recommendations:

These print way faster and stronger with a 0.6mm nozzle, but a 0.4mm will do the job.

Face plate should be printed completely solid for the most durability.  I increase top and bottom layers until it's completely solid rather than increase infill.  I also print the face plate with the counter sinks for the mounting screws facing the print surface.  This gives a nice texture on the front (when printing on textured print bed).

When printing in softer TPU, you will want 5+ perimeters to make the box stiff enough to hold its shape.  The harder the TPU, the fewer walls you need.

The 3/4 NPT version doesn't seem to need any support.  The overhangs on the threaded section aren't amazing, but they're good enough for the strain relief to thread in and hang on tight.  It is supposed to be a tight fit.

The appliance connector does want supports.  I've gotten away with no supports, but it's nowhere near as clean looking and it's harder to assemble.