Minimal Tophat using 4mm Coroplast sides, flexible dimensions, magnetic top panel, 35mm height

I tried to use a bunch of the tophat designs out there, but they all had various flaws.

• They used a LOT of material
• They tended to be quite size specific, made for specific Voron dimensions (I was building a conversion, so my frame was slightly different)
• They covered up the top side of the extrusion, making things like mounting an ERCF on TOP of your printer difficult.
• This also made mounting a pre-existing top panel solution difficult. I really liked these magnetic panels: https://www.teamfdm.com/files/file/595-magnetic-panels-with-magnet-inserts/ so this corner is built to mount magnets that fit those.
• My frame was a bit funny (Tronxy a5sa), it uses dilled holes in the top extrusion, killing 40mm in the Y dimension, and 20mm in X dimension of usable space where I could attach this to the frame, so I needed to make the corner just big enough (60mm) to allow secure attachment, the rest is all usable space closed off with Coroplast.

I tried to solve this with this design.

NOTE: this is probably due for a redesign, I learned a lot more about modelling since when I made this original version :)

The two piece design allows to minimize material used, the outer piece screews into the frame, while the inner piece is just held in place with some loosely added screws at the bottom.

The use of the Coroplast and the way its positioned (near the inner edge) exposes ~⅔ of the extrusion allowing for things to still be securely attached.

You need to print 4x the two models.

BOM:

• You will need strips of coroplast to connect the corners together, 35mm in height
• 8x 6x3 magnets like the mag panels BOM calls for
• A bunch of screws and hammer/drop in nuts