Available designs
Enclosure designs are provided for different hardware versions, with each design optimized for its corresponding PCB.Hardware v1 enclosure
Original enclosure design for v1 hardware boards
Hardware v2 v3 enclosure
Updated enclosure design for v2 hardware (v3 revision)
File locations
Enclosure files are organized by hardware version in theenclosure/ directory:
Each enclosure consists of two parts: a top cover and bottom base that snap or screw together around the PCB.
File formats
The enclosures are provided in multiple formats for maximum compatibility:STL files
STL (STereoLithography) files are the standard format for 3D printing:- BlueBus_Top.stl / BlueBus v3 Top.stl: Top cover piece
- BlueBus_Bottom.stl / BlueBus v3 Bottom.stl: Bottom base piece
STL files are ready to import directly into your slicer software (Cura, PrusaSlicer, Simplify3D, etc.) without any modification.
STEP files (v2 hardware only)
STEP (Standard for the Exchange of Product model data) files are CAD-native formats:- BlueBus v3 Top.step: Editable CAD model of top cover
- BlueBus v3 Bottom.step: Editable CAD model of bottom base
Edit designs
Import STEP files into CAD software to modify the enclosure design
Integration
Use STEP files to design custom mounting brackets or integration parts
- Fusion 360
- SolidWorks
- FreeCAD
- OnShape
- Other professional CAD software
Design features
The BlueBus enclosures are engineered for practical vehicle installation:Protection
- Fully enclosed PCB protection from dust and debris
- Ventilation slots for heat dissipation
- Cable entry points for connectors
- Strain relief for cables
Mounting
- Mounting holes for secure installation
- Compact profile fits behind vehicle dash
- Flat bottom for stable mounting
- Optional standoffs for cable routing
Assembly
Snap-fit design
Top and bottom pieces snap together without tools
Screw mounting
Optional screw holes for permanent assembly
Access
- LED visibility through top cover
- USB port accessibility
- Connector access without removing enclosure
- Easy disassembly for firmware updates or modifications
3D printing specifications
The enclosures are designed for FDM (Fused Deposition Modeling) printing with standard settings.Recommended settings
| Parameter | Value | Notes |
|---|---|---|
| Material | PLA, PETG, or ABS | PETG recommended for heat resistance |
| Layer Height | 0.2 mm | 0.15 mm for better surface finish |
| Infill | 20-30% | Higher infill for more rigidity |
| Perimeters | 3-4 | More perimeters for stronger parts |
| Supports | Usually not required | Check slicer preview |
| Orientation | Bottom on build plate | Top piece may need rotation |
PETG is recommended over PLA for automotive use due to better heat resistance and durability in vehicle cabin temperatures.
Print orientation
- Bottom piece: Print with the bottom surface (flat side) on the build plate
- Top piece: Print with the top surface facing up, no supports needed for most designs
Material selection
PLA
Easy to print, good surface finish, but lower heat tolerance
PETG
Best choice for vehicles - heat resistant and durable
ABS
Excellent durability, requires heated chamber
Post-processing
After printing, minimal post-processing is needed:- Remove supports (if used) with flush cutters
- Clean up any stringing or artifacts with a hobby knife
- Test fit the PCB before final assembly
- Smooth edges with fine sandpaper if needed
- Assemble top and bottom pieces
Test the snap-fit assembly before inserting the PCB to ensure proper fit. The parts should snap together firmly but not require excessive force.
Customization
The STEP files (available for v2 hardware) allow you to customize the enclosure:Modification ideas
- Add custom mounting brackets for your vehicle
- Integrate cable management features
- Add labels or branding to the exterior
- Modify ventilation patterns
- Create custom color schemes with multi-material printing
CAD workflow
- Import the STEP file into your CAD software
- Make your modifications
- Export as STL for printing
- Slice and print test pieces
- Iterate until satisfied
If you create improved enclosure designs or vehicle-specific mounting solutions, consider sharing them with the BlueBus community.
Hardware compatibility
Make sure to use the correct enclosure version for your hardware:| Hardware Version | Enclosure Directory | Notes |
|---|---|---|
| v1 | hw1_v1 | Original design |
| v2 | hw2_v3 | Current production, includes STEP files |
The enclosures are not interchangeable between hardware versions due to different PCB sizes and connector placements.
Assembly instructions
Basic assembly
- Insert PCB into the bottom enclosure piece
- Route cables through the appropriate openings
- Align connectors with access ports
- Place top cover over the PCB
- Press or snap the two halves together
- Optional: Secure with screws if screw holes are present
Mounting in vehicle
- Use double-sided automotive tape for temporary installation
- Use screws or zip ties for permanent mounting
- Ensure adequate clearance for cables
- Keep away from heat sources and moving parts
- Allow airflow around ventilation slots
Install the BlueBus in a location where you can access the USB port for future firmware updates without removing the entire assembly.
Troubleshooting
Common printing issues
| Issue | Solution |
|---|---|
| Parts don’t fit together | Check print scaling is 100%, verify dimensions |
| PCB doesn’t fit | Ensure correct enclosure version for your hardware |
| Weak snap-fit | Increase perimeter count or print with stronger material |
| Warping | Use heated bed, brim, or enclosure for printing |
| Poor surface finish | Reduce print speed, optimize temperature |