EMFCamp Tildagon Badge Top-Bumper/Cover

One of our EMF Camp badge screens got damaged, so I decided to design an enclosed cover for the badge combining a 3D printed bumper with a thin clear acrylic cover insert. The bumper does give some protection to the top LEDS and screen without the insert too, and if you wanted you could re-do the FreeCAD design to remove the inset. I initially designed this as just a straight padded hexagonal bumper but it felt too chunky to me, so I decided to make the top round which then transitions the whole badge nicely between its hexagonal form-factor to its round central screen.

There is also a discreet lanyard threading tube ("noodle" I call it) in one corner of the bumper, this is in the form of an enclosed “noodle” through the bumper which means it doesn't create a hole through which dust could get in, even safe from liquids running down the lanyard! Internal diameter of the noodle is about 4mm.

The acrylic insert can be cut out of 1mm acrylic on a CNC router - cut to the outside of the line in the supplied DXF file. For me this clips into the bumper very firmly. A little bead of some appropriate glue or silicone could perhaps make it more robust but I've not tried this yet.

I think it is particularly nice printed in a translucent material allowing the LEDs to shine through. I've used a glittery clear PLA for mine.

This can be used in conjunction with the screen shim I designed, which helps keep the screen level and stable.

I've included the full FreeCAD project file here so you can remix and modify as desired - this is actually my first ever full FreeCAD project (so perhaps some things I've done are non-normal/ideal - I'm still very much on L plates - but it prints well!)

Print Tips:

• I use a raft to ensure a good level base and avoid any elephant-footing issues. (Some minor post processing in the form of sanding the base is then helpful if you have any jaggy bits from raft adherence.)
• This prints ever so slightly smaller than the top PCB, I prefer it this way but you could try something like a 101% scaling factor to make it a little bigger (there should be enough tolerance in the screw holes for this). As I see it the PCB itself doesn't need protecting and I didn't like the feel of an initial slightly larger prototype I did versus the corner buttons.