I saw Lego Technic Frames a while back, and my immediate thought was they they were a perfect element to make custom enclosures. I've got detailed information on Jon's Imaginarium, a blog I've started to present tips, techniques and resources about electronics, laser cutting and other things that strike my fancy. The blog has a maker-focus, something not always a focus here.

Take a look at how to easily make custom enclosures and look around for others useful stuff.

 

Reproducing the frame using FDM printing and threaded inserts would be cheap, flexible, and more customizable. The geometry of the construction is the key here, I think. It does look handy.

 

A 3D printer has satisfied all my custom enclosure needs of late. Complete with battery compartment and PCB mounting.

 

A 3D printer has satisfied all my custom enclosure needs of late. Complete with battery compartment and PCB mounting.

Printing structural and oddly shaped parts while using sheet stock for large, flat areas does present some advantages. It can be quicker, it won‘t have layer lines which would possibly make it stronger and more aesthetically pleasing, and it could produced housings that exceed the build place capacity of the printer.

With a laser cutter, this hydrid approach is even more attractive.

 

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Another article on Jon's Imaginarium is about using Rowmark Colorcast Acrylic for panels. This material is 3mm thick clear acrylic, with a thin color layer on the back. You can laser-engrave through the color layer, then fill those areas with paint to create whatever labels and artwork you like. Since the artwork is on the back, and the front surface has a hard-cote finish, the panel can hold up to years of use and still look brand new.

Coupled with using the frames (Lego, 3D printed or Chinese knock-off) you have a professional looking enclosure.

 

One thing I have been noodling around for a personal project is a 19" rack enclosure. The Lego frames didn't lend themselves to the application because they don't line up well with the standard rack panel heights. Last night I saw the Lego 3x19 frame, which I never thought would be that useful....

Bingo. 1U height rack solution found! This frame would provide a 24mm internal height, but if that's not tall enough, the cover panel can be mounted on spacers.

 

If anyone is interested, I added SVG files to cut the pieces needed for a 1U 19"rack enclosure on Jon's Imaginarium.

Laser-cutting panels allow me to make panels that fit, the the needed holes accurately cut and positioned (my Dremel tool abilities to do so are sorely lacking!) Add the needed openings on these panels and you're good to go.