3D Printed Electronics Enclosures

After a dozen projects I have opinions on what makes a good 3D-printed electronics enclosure. PETG over PLA for anything that will be near heat sources — PLA starts creeping above 60°C. For outdoor enclosures, ASA is worth the extra cost because it doesn't UV-yellow.

Design tips: add 0.2mm clearance to all board mounting holes relative to the screw diameter. Use heat-set inserts instead of self-tapping screws for anything that will be opened repeatedly — you'll thank yourself after the third disassembly. Design cable glands into the case from the start rather than drilling holes later. For interference fits (lid lips), 0.15mm interference on each side is a good starting point and is easy to adjust.

For waterproofing, a thin bead of silicone around the lid gasket groove works. Don't rely on print-layer adhesion for water resistance — that fails over time as layers separate.