WLED ESP32 Enclosure

This is a case that will hold all the things to power your led lights(or anything else that needs an esp32) and keeps everything in one neat case. 

Many of the parts are things I had laying around, I will include links to the things I used at the bottom but that doesn't mean there aren't better options e.g. the power switch and plug don't have screw holes so I had to create a bracket to hold it. Case can definitely be optimized to be smaller, neater, use less hardware etc. but It gets the job done as is for me.

PLEASE CHECK YOUR EXPECTED POWER DRAW AND MAKE SURE YOUR WIRES ARE THICK ENOUGH FOR IT

Dimensions

210mm x 188mm x 81mm

Was designed for the following: 

• PSU(I'm using a 12v 10A unit, most 10A and 15A units tend to be the same size)

• 30-pin ESP32(with a breakout board)

• 12 Screw Terminal Block x2

• GX-16 connectors x4

• C14 Socket with Fuse and Switch

• 80x25mm Fan - optional

• 3.3V Buck Converter(MP1584) - optional

• KY-022 IR Sensor - optional

  • IR Remote

Hardware required

• M3 threaded inserts x12 (all components attached to the bottom and socket bracket)

• M4 threaded inserts x12 (all case screws)

• M3x8 screws x6 (ESP32 and PSU)

• M3x16 screws x6 (Terminal Blocks and Socket Bracket)

• M4x16 screws x4 (Wall to Floor screws)

• M4x8 screws x8 (All other case screws)

• If you use the IR Sensor

  • M2x8 screws x2

  • M2 nut x2

• If you use the fan

  • M4 screw and nut x2

Print Settings

I printed it all at 5% infill with PLA+ and its fine but a bit flimsy at 5%. I recommend at least 15% for the face plate since the power connector can take a bit of force to get in and out. Supports needed for the wall, just for the 4 mounting ears near the bottom

Recommendations and Notes

• Try to use jst connectors everywhere to make it a bit neater and easier to work with.

• The threaded inserts for the breakout board aren't perfectly placed but close enough to get 2 or 3 screws in which is more than enough. 

• The GX16 connectors just short enough to where the nut just barely threads on, I recommend removing the little ring it comes with to make it fit, and it grips better as well.

• The IR Sensor was a last minute addition so the placement might not be perfect for you so double check that for your setup.

• Fan

  • I used a cheap fan and its loud, would recommend something a little quieter if that matters for you(e.g. Noctua NF-A8 ULN).

  • Fan is optional but recommended since the PSU wont be in open air, consider it mandatory if you have more draw than 50% of your units capacity. 

  • 80x25mm fan is what i used

  • WLED works with PWM fans, I didn't use one but can be worth it if your worried about noise

• My socket doesn't have screw holes so I had to use the bracket, if yours does have screw holes then you wont need the bracket(though unsure if the holes will lineup).

• The buck converter isn't needed if you have a 5v PSU

Link to TinkerCAD file if you want to make changes
https://www.tinkercad.com/things/9tX8SljUICV-wled-case-v2

Links of what I used

• PSU - (https://www.amazon.ca/dp/B00FEYHNIE?ref_=ppx_hzsearch_conn_dt_b_fed_asin_title_9)

• ESP32 - (https://www.aliexpress.com/item/1005005704190069.html)

• Breakout Board - (https://www.aliexpress.com/item/1005007464906653.html)

• Terminal Block (https://www.aliexpress.com/item/1005006185265831.html) - 12 hole

• C14 Socket - (https://www.aliexpress.com/item/1005008209038658.html)

• GX16 - (https://www.aliexpress.com/item/1005008859055554.html)

• Buck Converter - (https://www.aliexpress.com/item/1005006365918330.html)

• Fan - (https://www.aliexpress.com/item/1005006306536871.html) - 80x25mm

Fan Grille I got from