Assignment Goal

For Week 2, the assignment was about computer aided design. I used this week to start planning the physical shape of my final project, which is a smart battery checker and charger. Before jumping into the final build, I needed to think about the enclosure, the screen, the charger boards, the battery connections, and how everything might fit together in one box.

This was still an early idea, so the goal was not to make the perfect final case right away. The goal was to get something modeled, look at the size, and start figuring out what would need to change later.

Rough Draft Sketch

I started with a rough paper sketch. This helped me think through the basic layout before I opened any CAD software. I wanted the screen on the front/top where it would be easy to see, and I wanted room for the battery connections, charging modules, wiring, and PCB inside the enclosure.

The sketch was not fancy, but it gave me a starting point. It helped me see that the enclosure needed to be more than just a simple box. I had to think about access to ports, screw holes, wire space, and how the project could be opened again if I needed to repair or change something.

Why I Used Tinkercad

I used Tinkercad for this first design because it is simple and fast for basic shapes. Since the first enclosure was mostly a box with cutouts, Tinkercad made sense. I could use solid boxes, hole boxes, cylinders, and simple alignment tools without getting slowed down by a more advanced CAD program.

For a first version, I cared more about testing the size and layout than making a perfect production model. Tinkercad let me move quickly and get a model ready to print.

Tinkercad Modeling Process

I started by making the outside box shape. Then I used a smaller box set as a hole to hollow out the inside. This gave me space for the ESP32 screen, charger modules, battery connections, PCB, and wiring.

After the shell was made, I started planning the lid and the mounting holes. I wanted to use brass heat-set threaded inserts so the lid could be screwed down and removed later. That matters because electronics projects usually need opened back up for testing, fixing wires, or changing parts.

I also planned side openings for USB-C charging ports and wiring connections. The first model was not perfect, but it helped me understand the real size of the enclosure and how much space the electronics might need.

Original Design Files

After modeling the enclosure, I exported it from Tinkercad as an STL file so I could slice it and 3D print it. I also kept the original Tinkercad design so I could go back and edit it later as the final project changed.

• Original CAD design: Tinkercad enclosure model
• Exported file type: STL
• Purpose: early enclosure prototype for my smart battery checker and charger
• Main design idea: box-style enclosure with room for screen, charger boards, PCB, and wiring

3D Printing the Enclosure

After the model was ready, I prepared it for 3D printing. I chose PETG carbon fiber because it is stronger than basic PLA, has a clean dark look, and seemed like a better material for a project enclosure.

This print was the first physical version of the enclosure. Printing it helped me see the real size of the box and showed me what would need to change. Things like the screen opening, side ports, wire clearance, and insert holes are easier to judge once the part is actually in my hands.

Image and File Compression

I also worked on understanding file size for documentation. Fab Academy websites can get messy fast if the pictures are too large. Big photos make the website slower and can make uploads harder to manage.