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In-Wall Sonoff Light Switch v2

by 530_Projects, published

In-Wall Sonoff Light Switch v2 by 530_Projects Nov 8, 2017
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Design Tools

Fusion 360

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Thing Statistics

3196Views 246Downloads Found in Electronics

Summary

This is version 2 of my DIY Sonoff Light Switch. In the comments of my first version, it was mentioned that I should use the existing button on the sonoff instead of needing to add a pcb and two additional buttons. I thought that was great idea and I went to work. I took a few iterations of the paddle before the operation was smooth, but I am finally happy with how it functions.

And same as before, I am offering these files for free, all I ask is that you subscribe to my youtube channel and maybe like and share the video if you think the project and video deserves it. It doesn't cost you anything to subscribe, and it encourages me to share more of my projects with the community.

You can find the code that I used for v2 on my github page (linked in the video description).

This is the overview video that explains what is different in v2. https://www.youtube.com/watch?v=OK1kWAeawQA

Please watch the assembly video for tips on how to assemble without breaking the actuator. https://www.youtube.com/watch?v=lnv1YRf7uRA

For reference you can find v1 here: https://www.thingiverse.com/thing:2562998

Print Settings

Printer Brand:

Wanhao

Printer:

Wanhao Duplicator i3 V2

Rafts:

Doesn't Matter

Supports:

Yes

Resolution:

0.2

Infill:

30%

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This is a really neat project- thank you. Have you ever considered doing a "Decora" style switch?? Thanks!

+1 for that. all mine are decora, but would like to setup a couple of these.

Wow, this looks so very interesting! I'm really glad I stumbled on your Youtube video and that you were kind enough to post your STL's here.

My only issues are going to be:

1) Aesthetics: Even the nicest 3D printed switch isn't going to match my other switches.
2) Safety: For some reason I'm just nervous about having this in the wall. Maybe that's unfounded?

Again, thanks so much for posting the videos and the thing files!

Re these compatible with existing light switches? Can i swap my old ones out for this?

Yes, as long as your existing light switch is the only switch that controls the light (like in a bedroom or closet). It will not work to replace a light switch where there are multiple switches controlling the light (like at both ends of a hallway). This is because the sonoff is SPST (Single Pole Single Throw) relay and you don't have a normally closed pin on the relay.

I'm wondering if it would fit in the existing hole and the existing light switch cover. Basically does it have the same dimensions

I designed this switch by taking dimensions from my existing switch. And I directly replaced my existing switches without any modifications to the wall, the electrical box in the wall, or the existing switch cover. I am confident that if you house was built in the USA within the last 30 or so years, then it will fit the existing hole and the existing light switch cover.

I modified the case and face to add a third tab to hold them together better, and modded the toggle into a rocker.
If interested I'll up load them

If you're using mains current (which I can't tell from the photo), something to consider Is that real gang boxes are designed to contain sparks if there is an electrical short. So they are made of fire retardant plastic to keep your house from burning down. But PLA and ABS are flammable.

Your concern is a good one and very real however it may not be as big of a concern as you think. It does use mains power but about the only thing doing anything with it is a relay that should already be flame resistant. There are a lot of these in use and they seem really well designed so an issue is really unlikely. The standard case is also plastic but they do not seem to have that sort of issue. There is a Youtube of someone who overloaded the 10A one to 20 amps and a trace let loose acting sort of like a fuse. Look up John Ward...

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