Laser cut acrylic cases for 96Boards Consumer Edition

TL;DR: There are some tried and tested CAD files and the DXF files can zipped and sent directly to the Seeed Studio laser cutting service.

Simple case for 96Boards Consumer EditionI have amassed a modest collection of 96Boards. They come as plain circuit boards with nothing to keep them safe from damage during handling. Its not just static discharge we have to worry about! Many of the boards have fairly large components on the underside and these can be knocked off by careless handling (I admit that I’m tempted to say “Hi” to a colleague at this point, but I won’t). Since, I’m at least as careless about handling as the next software engineer so I decided a case was needed.

I’m not aware of anyone selling cases for the 96Boards Consumer Edition so I decided to get my own laser cut. As it happens between ordering the boards and writing this post I have started to come across a couple of other folks at Linaro who are experimenting with cases but nevertheless I think I’m still the first to blog about it!

There is a hackspace in Bristol, UK where I live which could be a great place to get involved in laser cutting but it’s right on the other side of the city and I’ve not really found the time to get very involved there. Instead I decided to try out the Seeed Studio online laser cutting service: 100mm x 100mm, cut to your own design for $6 for five (plus postage).

Having something of a plan the only remaining problem is that I know absolutely nothing about CAD/CAM. The only information on the Seeed Studio website about file formats is that I must send in .zip or .rar files and the only blog posts I could dig up wanted me to use the Google Sketchup which is non-free and partially discontinued.

In the end I just asked myself, “How hard can it be?” and fired up LibreCAD. After working through a couple of tutorials I learned how to round off corners and how to add dimension information. Armed with this, and the 96Boards CE Specification which has very clear diagrams of the physical layout of the board, I draw a basic top/bottom plate. I wasn’t happy with the 35mm of “wasted” material due to the minimum panel size of the manufacturer so I added a half-top component as well. The half-top should work very nicely with the 96Boards UART board.

Combo case for 96Boards Consumer Edition

Influenced by this blog post I decided to export from LibreCAD as an SVG. This turned out not to be such a great idea. The resulting SVG uses curves that are quantized to pixelish boundaries. The friendly folk at Seeed Studio declined to use it and askeld me for DXF files instead. Since DXF is the native file format for LibreCAD this was not much of a hardship.

And that’s it… I got a bunch of cases made in a couple of colours. The glowing neon green in the photo above is sooooo my favourite. I’ve hurled my design files at github and, because I’ve had so much fun with this, I’ve given the project a nice generic name. Maybe there are more cases to come. If that happens, you’ll read about it here first!

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