Weather Station Enclosure for a Stevenson Screen — ESP32-C3 + AHT20 + BMP280 + Rain Sensor (Support-Free)

Ventilated, support-free enclosure for a DIY weather station living inside a Stevenson screen. The ESP32-C3 Super Mini and the LM393 rain-sensor controller sit side by side in the main box; the AHT20 and BMP280 live in two separate louvered pods bolted to opposite ends — thermally isolated from the ESP32's heat for accurate readings. The rain detection panel mounts outside.

Designed entirely with Claude.ai — the parametric Python script (included), all STLs and the ESPHome config came out of a plain chat conversation, no CAD software involved. Edit two numbers in weather_box.py (or just ask Claude) and regenerate if your boards differ. The only exception is outdoor-weather-station-rain-holder.stl (the mount for the rain detection panel) — that one is my own design, not Claude's.

Features

• Zero supports on all 4 parts — the pods use 45° hip roofs instead of flat ceilings

• Sensor pods detach with 2 bolts each, sensor comes out with the pod — no need to open the main box

• Board cradles with raised seats (5 mm clearance for soldered pins underneath) and zip-tie slots

• USB-C accessible from outside for flashing/power

• Ventilation slots on walls, floor, lid and pods — it's a radiation-shield enclosure, airflow over hermeticity

Print

• Material: PETG or ASA (skip PLA — summer heat will warp it)

• Layer: 0.2 mm, 3 perimeters, 20–30 % infill

• Orientation: as exported (pods flange-down), no supports, no brim needed

• Print the pod twice (two identical files included)

Hardware

• 8× M3×3 heat-set inserts (Ø4.0 pockets — adjust in the script if yours differ)

• 8× M3×8 bolts

• A few thin zip ties

Assembly in short

Press 4 inserts into the corner bosses (lid) and 2 into each end wall from the outside. Zip-tie the boards into their cradles, ESP32 with USB-C facing the wall opening. Feed each sensor's wires through the Ø8 wall hole, slide the sensor into the pod through the flange opening, bolt the pod on — the wall closes the opening. Rain panel wires exit through the Ø6 hole in the back wall.

ESPHome config and full build story: see the linked Instructable.