Second generation enclosure design for ESP32-S3 based LAN IoT devices with improvements based on V1 feedback.
Disclosure: As an Amazon Associate I earn from qualifying purchases made with links from the products on this document.
IoTBox V2 is the current production enclosure design for the LAN IoT project. This version incorporates lessons learned from V1 with improved assembly, ventilation, and overall usability.
✅ Current Production Design - Recommended for all new deployments.
IoTBoxV2-BOTTOM.stl- Base enclosure for 3D printingIoTBoxV2-TOP.stl- Top cover/lid for 3D printingIoTBoxV2.FCStd- FreeCAD source file for modifications
| Feature | V1 | V2 |
|---|---|---|
| Size | Length 75mm | Lenght 52 |
| Ventilation | No vents | Optimized airflow design |
| Assembly | 4 steps | Simplified to 3 steps |
| Lid Attachment | NONE | Snap-fit |
| Support Material | Heavy | Minimal supports needed |
- 🔧 Snap-fit Design - Easy assembly without tools
- 🌬️ Enhanced Ventilation - Improved heat dissipation
- 📡 Optimized RF Performance - Better WiFi antenna placement
- 🔌 Organized Cable Routing - Dedicated channels for cables
- 🏭 Industrial Mounting - Multiple mounting options
- 🖨️ Print-Friendly - Minimal support material required
- Material: PLA or PETG (PETG recommended for industrial use)
- Layer Height: 0.2mm
- Infill: 20% (30% for industrial environments)
- Supports: Minimal (auto-support recommended)
- Print Orientation: Both parts bottom-down
- Wall Lines: 3 (for strength)
- Top/Bottom Layers: 5
- Bottom: ~3-4 hours
- Top: ~1-2 hours
- Times vary based on printer and settings
| Material | Pros | Cons | Use Case |
|---|---|---|---|
| PLA | Easy to print, rigid | Lower heat tolerance | Indoor, moderate temps |
| PETG | Durable, heat resistant | Requires tuning | Industrial, outdoor |
| ABS | Very strong, heat resistant | Requires heated chamber | Harsh environments |
- 3D printed bottom enclosure
- 3D printed top cover
- Seed Studio XIAO ESP32S3 development board
- Perfboard 47x34mm for assembly
- RS232 to TTL Serial Port Module
- Right Angle Tactile Button
- Pin Headers and Jumper Wires
- M3 x 10mm screws (4x) - optional for secure lid
- Rubber feet (4x) - optional for standalone mounting
-
Prepare Components
- Clean 3D printed parts (remove support material)
- Test fit all components before final assembly
-
Install Components on Perfboard
- Mount ESP32S3 on perfboard
- Solder pin headers as needed
- Install RS232 module on perfboard
- Add tactile button for GPIO3
-
Wire Connections
- Use jumper wires for connections
- Connect TX (GPIO44) to RS232 RX
- Connect RX (GPIO43) to RS232 TX
- Connect GPIO3 to tactile button
- Connect 3V3 and GND as needed
-
Cable Management
- Use provided routing channels
- Secure cables with small zip ties if needed
- Ensure cables don't block ventilation
-
Close Enclosure
- Align top cover with bottom
- Press firmly to engage snap-fit
-
Mounting (Choose one)
- Standalone: Put in top of the table, connected directly to the serial device
- Dimensions: 48mm x 36mm x 21mm (internal)
- Perfboard Size: Designed for 47x34mm perfboard
- ESP32 Module: Fits Seed Studio XIAO ESP32S3 (21mm x 17.5mm)
- Component Space: Room for RS232 module, button, and connectors
- Ventilation: 22mm x 5mm vents
| Item | Quantity | Notes |
|---|---|---|
| Seed Studio XIAO ESP32S3 | 1 | Or compatible board |
| Perfboard 47x34mm | 1 | For component mounting |
| RS232 to TTL Serial Port Module | 1 | RS-232 communication |
| Right Angle Tactile Button | 1 | Reset/function button |
| Pin Headers 6 PIN Female | 1-2 | Connectors |
| Jumper Wires/Breadboard Cables | Set | For connections |
| USB-C Cable | 1 | Power and programming |
| Item | Quantity | Notes |
|---|---|---|
| M3 x 10mm Screws | 4 | Optional for secure lid |
| Soldering Iron | 1 | For perfboard assembly |
| Solder | 1 roll | 60/40 or lead-free |
| Wire Strippers | 1 | For wire preparation |
| USB-C Cable | 1 | Programming and power |
- Electronics: ~$20-25 USD
- Hardware: ~$0 USD
- 3D Printing: ~$2-3 USD material cost
The FreeCAD source file enables easy customization:
- Adjust Size - Scale for different ESP32 modules
- Add Connectors - Custom cutouts for specific connectors
- Branding - Add logos or labels to top cover
- Mounting - Add custom mounting features
- Cooling - Modify ventilation for specific needs
- Open
IoTBoxV2.FCStdin FreeCAD - Use parametric features to maintain design integrity
- Export modified parts as STL for printing
- Test fit before final print
FreeCAD Download: freecadweb.org
Reference photos available in images directory:
- Assembly sequence
- Component placement
- Cable routing examples
- Mounted installations
- All components properly seated
- USB port accessible
- Ventilation not blocked
- WiFi antenna properly positioned
- All connections secure
- Test power-on and connectivity
- Operating Temperature: -10°C to 50°C
- Maximum Internal Temp: Should not exceed 60°C under normal operation
- Ventilation Check: Ensure vents are clear
| Issue | Cause | Solution |
|---|---|---|
| Lid won't snap | Part warping | Check print quality, try screws |
| Overheating | Blocked vents | Clear ventilation, check placement |
| WiFi weak | Antenna position | Reposition antenna, check routing |
| USB access difficult | Misalignment | Check ESP32 mounting position |
We're working on V3 with:
- External antenna for beter Signal
- Tool-less DIN rail mounting
- Optional display window
- IP54 rating for outdoor use
Feedback welcome: GitHub Issues
- Issues: Report on GitHub
- Discussions: Community Forum
- Consulting: LinkedIn - Carlos Huggins
Hardware design licensed under Apache License 2.0. See LICENSE.
Ready to Build? Follow the Quick Start Guide after assembly.