{"id":655,"date":"2012-04-19T18:02:19","date_gmt":"2012-04-20T02:02:19","guid":{"rendered":"http:\/\/www.roastgeek.com\/wordpress\/?p=655"},"modified":"2012-06-06T19:51:38","modified_gmt":"2012-06-07T03:51:38","slug":"adventures-in-custom-cases","status":"publish","type":"post","link":"https:\/\/www.roastgeek.com\/wordpress\/2012\/04\/19\/adventures-in-custom-cases\/","title":{"rendered":"Adventures in Custom Cases"},"content":{"rendered":"\r\n\t\r\n\t

The more I look at my project and the fact that it TECHNICALLY does in fact roast coffee now… and the more I think about it the more I feel I need to work on a better project enclosure for my project.\u00a0 While the Radio Shack case is fine I have concerns with the layout I had to use for the in-progress prototype plain taking up too much space.\u00a0 I feel like I need to move on to building something that is (at least on the outside) more permanent.<\/p>\n

When I look at the schematics and all the wiring involved I keep seeing situations where I need to shrink it all down onto a custom made board.\u00a0 The more I think about a board (as rendered a few weeks ago in a previous post) I realize I need a box that it will go in figured out.\u00a0 Once I know the box shape the better I can layout a board since I will finally have “internal dimensions” to try to squeeze it all into.\u00a0 How to build a case, however, is not entirely easy.<\/p>\n

Sure there are blogs all over about people building cases for their projects but most of them assume a standard rectangular box.\u00a0 The sides all interlock together and you anchor it with some slots cut into the box and a set of bolts\/nuts for each corner\/side\/whatever.\u00a0 Outside of those sort of cases there are very few options as a DIY case unless you have welding capabilities or other more advanced tools at home like a mini-CNC or something like that.<\/p>\n

There are plenty of sites that offer to fabricate stuff for you.\u00a0 Ponoko tends to one of the more popular ones.\u00a0 There are also other more “professional” ones that allow much more advanced cases to be built.\u00a0 These sites include those such as Protocase and Front Panel Express.\u00a0 Both of those offer free software that you can use to design a case.\u00a0 Protocase offered a pretty interesting tool that actually creates a 3D case made from various metals and are quite impressive.\u00a0 The issue is they are also VERY impressively expensive.\u00a0 The deal is, however, that they do offer “console” type cases that are customizable quite a bit and will allow you to see a complete all around view of the case.\u00a0 The problem is that you cannot do anything with the file they give you other than to send it in and buy it from them.<\/p>\n

Front Panel Express offered a much more open proprietary tool.\u00a0 This tool you can export the completed panel to a DXF file which can be imported into many other software packages, including those used on the suggested list for Ponoko.\u00a0 While they don’t really want you to use their software to build a panel at another vendor, of course, it DOES actually work out.<\/p>\n

Another issue with the Front Panel Express is that it only allow you to design one panel at a time.\u00a0 Each side Left\/Right\/Rear, Front, and Back in addition to your Top control area needs to be built separately.\u00a0 They make a lot of their panels out of aluminum or steel and have quite a lot of capability to build most anything you want.<\/p>\n

The issue?\u00a0 The following:<\/p>\n

\"\"<\/a><\/p>\n

At the cheapest this seems to run around $65 for only this panel.\u00a0 You can save a bunch of money by drilling your own holes for the countersunk screws and the round holes and instead just having them marked using an engraving to help center your drill bit.\u00a0 I’m not against paying $65 for it BUT I feel that I need something cheap so I can confirm the layout REALLY is good even if I’ve rendered it in 3D.\u00a0 I need to mount everything in the holes and confirm that yes it DOES fit properly and there are no heat issues or anything else to make me need to move anything.<\/p>\n

Enter Ponoko.\u00a0 When I import the DXF into Google Sketchup it does all sorts of weird things with the text and a few other things depending on the design.\u00a0 When I try to raise\/lower the material it does some odd things as well because of some of the lines etc.\u00a0 What works better?\u00a0 I dug out CorelDraw and found I could tweak the Front Panel Express file in there quite well, export it, and load it into Ponoko’s system.\u00a0 It appears to look ok in there and allows you to use wood, cardboard, plastic, and a variety of other items.<\/p>\n

I took the outside dimensions of the FPE designed panel as well as the other measurements from some of the cut outs and dropped them into a few shapes in Google Sketchup.\u00a0 I then rotated the “rough” panel up 30 degrees since that seemed like a good amount and then attempted to measure the size of the effective foot print.\u00a0 I then threw together a small 1 inch base and then raised the top edge up the two sides up 30 degrees as well.\u00a0 I then slid them together and came up with this rough case package.<\/p>\n

\"\"<\/a><\/p>\n

Using the exported DXF for Ponoko in Acrylic after modifying a few items to make it compatible to Ponoko the front panel ended up around $15.\u00a0 At this time I haven’t purchased it since I need to make sure all the measurements are correct.\u00a0 Additionally I need to add the sides now that I’ve gotten measurements confirmed in Sketchup to a layout.\u00a0 I’m expecting the entire thing to run around $45 at Ponoko for the initial testing versions.<\/p>\n

The version in the rendering of course isnt entirely right.\u00a0 The LCD is actually slid up a little bit and the buttons go up as well.\u00a0 Each button ACTUALLY is supposed to be rounded on one of the sides and the two round holes on the left and right are for the potentiometers that should have an LED above them.\u00a0 The top needs an LED and there needs to be screw holes in a variety of places as well as some engraving to label things.<\/p>\n

At this time I intend to figure out the distances to the LCD edges and adjust the base width as needed when I find the ACTUAL dimensions of the LCD panel that will be used with a mount designed to secure it.\u00a0 I will then come up with a back panel and then start having this made.\u00a0 I will have plastic panels made by Ponoko and when I’m certain that I am pleased with the dimensions\/shape and fit I will have FPE build an anodized aluminum case for whatever it costs.<\/p>\n

Due to the 30 degree angle and the fact I did not want to use tabs to lock it together I wanted to be sure of my decades old “trig” knowledge when calculating triangles.\u00a0 The Sketchup Layout works well to see if the dimensions look good.\u00a0 As long as it all fits together a Ponoko build will let me see a physical model for final confirmation and showing it off before I get a permanent case made.<\/p>\n

Anyway I’m thinking for the buttons I’m going to use some MultiMec 1V16 white buttons for the directions, The middle button is currently planned as the 1T type buttons for an “OK\/Select”.\u00a0 I’m don’t think I can get them pre-labeled though so I might have to switch to a different button or do without labeling.\u00a0 Then the two at the top that are round would be for some sort of Escape\/Cancel and perhaps a dedicated stop\/end\/cool\/whatever.\u00a0 I need to confirm out which buttons to use so I can get whatever I need labeled well enough.<\/p>\n

In the position of the potentiometers I might switch them out for rotary encoders to help setup things a different way.\u00a0 Where the LCD is I will start with a panel that will fit in place of the full sized LCD using a smaller 4 line LCD until I start building the PIC32 system into it.\u00a0 Once I get to that stage I need to mount the LCD panel onto a backer that screws in place.<\/p>\n

If I could scrape together enough cash I’d get some sort of mini CNC machine and perhaps etch some buttons with ESC \/ OK \/ COOL or something like that as well as arrows and then infill them with some black.\u00a0 Totally way involved for a few buttons but would probably look pretty impressive.\u00a0 If I could make my own panels that would certainly negate the need for another vendor making the final panels.\u00a0 Too bad those machines are so spendy.<\/p>\n

I had ordered some motor controllers from a company in China back at the very beginning of the month.\u00a0 They shipped from the seller after some Chinese holiday or something.\u00a0 Apparently they went to some company that handles shipping things to the US or something before it went to their post office.\u00a0 It left China about a week ago and arrived in the international mail portion of some facility in Los Angeles a few days ago.\u00a0 It appears today it made it to the REGULAR Los Angeles post office sort facility.\u00a0 It should probably arrive in one of the Northern California sort facilities tomorrow and MAY make it my local post office.\u00a0 As I’ve come to expect anything coming from China seems to require a signature 9 times out of 10 so I will probably need to go to the post office on Monday to sign for it.\u00a0 So we’re around 20 days from when it was ordered.\u00a0 I’m trying to see if I can control the fan motors differently in some way that would make it more stable and give me a few options for actually building my own roaster later on using much larger blower fans and some other motors for opening\/closing vents.<\/p>\n","protected":false},"excerpt":{"rendered":"

The more I look at my project and the fact that it TECHNICALLY does in fact roast coffee now… and the more I think about it the more I feel I need to work on a better project enclosure for my project.\u00a0 While the Radio Shack case is fine I have concerns with the layout I had to use for the in-progress prototype plain taking up too much space.\u00a0 I feel like I need to move on to building something that is (at least on the outside) more permanent. When I look at the schematics and all the wiring involved \u2026 Continue reading → <\/span><\/a><\/p>\n","protected":false},"author":3,"featured_media":0,"comment_status":"open","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"jetpack_post_was_ever_published":false,"_jetpack_newsletter_access":"","_jetpack_dont_email_post_to_subs":false,"_jetpack_newsletter_tier_id":0,"_jetpack_memberships_contains_paywalled_content":false,"_jetpack_memberships_contains_paid_content":false,"footnotes":"","jetpack_publicize_message":"","jetpack_publicize_feature_enabled":true,"jetpack_social_post_already_shared":false,"jetpack_social_options":{"image_generator_settings":{"template":"highway","default_image_id":0,"font":"","enabled":false},"version":2}},"categories":[114,116,8],"tags":[],"class_list":["post-655","post","type-post","status-publish","format-standard","hentry","category-cases-enclosures","category-laser-cutting","category-roaster"],"wppr_data":[],"yoast_head":"\nAdventures in Custom Cases - Roast Geek<\/title>\n<meta name=\"robots\" content=\"index, follow, max-snippet:-1, max-image-preview:large, max-video-preview:-1\" \/>\n<link rel=\"canonical\" href=\"https:\/\/www.roastgeek.com\/wordpress\/2012\/04\/19\/adventures-in-custom-cases\/\" \/>\n<meta name=\"twitter:label1\" content=\"Written by\" \/>\n\t<meta name=\"twitter:data1\" content=\"SteveS\" \/>\n\t<meta name=\"twitter:label2\" content=\"Est. reading time\" \/>\n\t<meta name=\"twitter:data2\" content=\"8 minutes\" \/>\n<script type=\"application\/ld+json\" class=\"yoast-schema-graph\">{\"@context\":\"https:\\\/\\\/schema.org\",\"@graph\":[{\"@type\":\"Article\",\"@id\":\"https:\\\/\\\/www.roastgeek.com\\\/wordpress\\\/2012\\\/04\\\/19\\\/adventures-in-custom-cases\\\/#article\",\"isPartOf\":{\"@id\":\"https:\\\/\\\/www.roastgeek.com\\\/wordpress\\\/2012\\\/04\\\/19\\\/adventures-in-custom-cases\\\/\"},\"author\":{\"name\":\"SteveS\",\"@id\":\"https:\\\/\\\/www.roastgeek.com\\\/wordpress\\\/#\\\/schema\\\/person\\\/80c8f23278bfd9eafb058da60fcd10d1\"},\"headline\":\"Adventures in Custom Cases\",\"datePublished\":\"2012-04-20T02:02:19+00:00\",\"dateModified\":\"2012-06-07T03:51:38+00:00\",\"mainEntityOfPage\":{\"@id\":\"https:\\\/\\\/www.roastgeek.com\\\/wordpress\\\/2012\\\/04\\\/19\\\/adventures-in-custom-cases\\\/\"},\"wordCount\":1657,\"commentCount\":2,\"publisher\":{\"@id\":\"https:\\\/\\\/www.roastgeek.com\\\/wordpress\\\/#organization\"},\"image\":{\"@id\":\"https:\\\/\\\/www.roastgeek.com\\\/wordpress\\\/2012\\\/04\\\/19\\\/adventures-in-custom-cases\\\/#primaryimage\"},\"thumbnailUrl\":\"http:\\\/\\\/www.roastgeek.com\\\/wordpress\\\/wp-content\\\/uploads\\\/2012\\\/04\\\/fpe-panel-344x400.jpg\",\"articleSection\":[\"Cases \\\/ Enclosures\",\"Laser Cutting\",\"Roaster\"],\"inLanguage\":\"en-US\",\"potentialAction\":[{\"@type\":\"CommentAction\",\"name\":\"Comment\",\"target\":[\"https:\\\/\\\/www.roastgeek.com\\\/wordpress\\\/2012\\\/04\\\/19\\\/adventures-in-custom-cases\\\/#respond\"]}]},{\"@type\":\"WebPage\",\"@id\":\"https:\\\/\\\/www.roastgeek.com\\\/wordpress\\\/2012\\\/04\\\/19\\\/adventures-in-custom-cases\\\/\",\"url\":\"https:\\\/\\\/www.roastgeek.com\\\/wordpress\\\/2012\\\/04\\\/19\\\/adventures-in-custom-cases\\\/\",\"name\":\"Adventures in Custom Cases - 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