LEDBox modular parametric enclosure for HUB75 LED matrix panels (P1 to P5)

LEDBox is an enclosure for a single row of HUB75 LED matrix panels, the kind sold as P2, P2.5, P3, P4 and P5. I designed it for a live train departure board made from four P4 256 × 128 mm panels, giving a 1024 × 128 mm display.

It prints as short sections that stack end to end on two M5 threaded bars, so a sign over a metre long comes off an ordinary 256 mm printer with no supports.

There is a github with better instructions here including how to customise in Fusion 360: https://github.com/eehackspace/LEDBox

Features

• One-piece channel sections, printed standing on end

• Two M5 threaded bars clamp the whole row together

• Rounded end caps, one with an opening for a mains inlet and one with mounts for a controller board

• Front groove for a 3 mm tinted acrylic sheet

• Nut slot along the top for hanging by chain or wire, and keyholes in the back for wall mounting

• Space inside for a Mean Well LRS-35-5 or LRS-50-5 power supply

• Screwdriver holes in the back so panels can be fixed from behind

Thick or thin?

Two versions are included. They fit together the same way and use the same hardware.

• Thick: 2.4 mm walls with stiffening ribs, about 122 cm³ per section. Choose this for public or knock-prone places.

• Thin: 1.6 mm walls, about 77 cm³ per section, so roughly 40% less plastic and print time. Fine for indoor use.

What to print (four P4 256 × 128 panels)

• 1 × section-vented-psu

• 6 × section-plain

• 1 × section-plain-mirrored-end

• 1 × end-cap-mains

• 1 × end-cap-controller

• Up to 7 × joiner-key (optional)

• 1 × test-slice (recommended first)

Print settings

• PETG or ASA. PLA is only suitable for test pieces.

• No supports.

• Stand the sections on end, with the end where the bar tubes reach the face on the bed.

• End caps print with the outer end face down.

• 0.2 mm layers, 0.4 mm nozzle. Thicker layers or a 0.6 mm nozzle shorten the print a lot.

Hardware

• 2 × M5 threaded bar, cut to 990 mm, with 4 nuts and 4 washers

• M3 screws for the panels, 6 to 8 mm

• 4 × M3 heat-set inserts and 4 × M3 screws for the end caps

• 3 mm acrylic sheet, 132 × 1024 mm

• M5 square nuts and eye bolts for hanging

• 5 V power supply and a fused IEC C14 inlet, if you want the supply inside

Other panel sizes

The included STL files are for four P4 256 × 128 panels. The Fusion file is parametric, with 19 common panel sizes from P1 to P5 built in as presets, and the README has step-by-step instructions for changing it that assume no Fusion experience.

Screw positions vary between panel makers, so measure your panel and print the test slice before printing a full set.

Fusion files, STLs and full instructions: Here

Please note

This is an early release. I have printed test slices but have not yet assembled a complete enclosure, and a few dimensions (panel thickness, power supply mounting holes, controller hole spacing) are estimates. Check the fit on your own parts first.

If you put a mains power supply inside, earth it, fit its terminal cover, use a fused inlet with strain relief, and keep the vents clear. If you're not confident with mains wiring, use an external 5 V supply.