This is a hinged case mode from a rounded rectangular prism (superellipse or Squircle https://en.wikipedia.org/wiki/Squircle) bent into a crescent by inversion on a sphere (https://en.wikipedia.org/wiki/Inversion_in_a_sphere). This was then sliced and lips and hinges added. Internal ribs to improve printing were added. Holes were made for a latch. Latch hardware and accessories were designed and added.
Note that a PS4 DualShock 4 controller fits in the case.
I printed the case out of PLA, but I have printed similar things with PETG without too much trouble.
If you want to try making a box with this wort of hinge before committing to this large a print, try https://www.thingiverse.com/thing:3407459. That project and this one use the same hinge arms. The files here use a 1.81 mm hole which has worked well with several different filaments.
Print of each of the following STL files:
blob40_1_hinge_screw_bot.stl Needs support material, print with curve up, took approx 20 hours to print on a Prusa i3 Mk2 w/ 0.4mm nozzel, and 0.2 mm layers.
blob40_1_hinge_screw_top.stl Needs support material, print with curve up
Assemble the hinges
See https://www.thingiverse.com/thing:3407459 for a closeup of the hinge pieces and how they go together.
Try pushing a long piece of 1.75 mm through all of the hinge holes first to make sure they are not blocked up.
Use 1.75 mm filament for the hinge pins and hold them in place by flattening the ends with a soldering iron separated from the plastic with aluminum foil. Some foil may stick, but it does not matter and can be trimmed easily.
Attach the latch hardware with 6 1/4" 4-40 screws and nuts, or M3 screws.
- Outside and inside STL files made with Octave
- Shells made with lips by OpenSCAD
- Hinges and latch related details added by OpenSCAD
- Hinge Arms and Latch components made with OpenSCAD