Dev Log: HackPad1 Custom Enclosure

Status: CAD Complete | Ready for Slicing & 3D Printing

Finally completed the custom enclosure for HackPad1.

The enclosure is a simple two-piece design that houses the 9-key switch matrix, OLED display, rotary encoder, and the USB-C microcontroller. Since this was my first proper CAD project in Fusion 360, I spent a good amount of time understanding the workflow while designing it.

Top Plate

The biggest issue I faced was creating the top plate.

Fusion 360 kept selecting the PCB and switch bodies instead of the sketch, making it difficult to select the regions between the switches for extrusion.

To work around this, I first created a solid 1.5mm plate covering the entire top. Then I turned the sketch back on and used a -1.5mm cut extrusion to create all nine switch cutouts. This approach worked well and saved a lot of time.

USB-C Cutout

Next, I worked on the USB-C opening.

I projected the USB connector onto the back wall and added some clearance so that different USB-C cables would fit comfortably.

While checking the design, I realized the back wall was too thick. A standard USB-C cable wouldn’t be able to fully connect because it would hit the plastic before reaching the port.

To fix this, I created a recessed pocket around the USB opening, reducing the wall thickness only in that area. This allows the cable to plug in properly while keeping the rest of the enclosure strong.

Finalizing the Design

Once everything was in place, I saved the project as a Standard Design and exported both the top plate and bottom enclosure as mesh files for printing.

Hackatime

Unfortunately, I couldn’t track today’s work on Hackatime because I couldn’t find a Hackatime extension for Fusion 360.

Although today’s work won’t appear in my Hackatime stats, it took a considerable amount of time. Since I’m completely new to CAD and Fusion 360, a large part of the process involved learning the software, understanding different tools, and refining the design through multiple iterations.