G302/303 top shell honeycomb

Last crawled date: 4 years, 2 months ago

Edit 11/11/2019 - added a new version of the flat top shell with the posts aligned tighter and slightly larger hex holes (2.1mm instead of 2mm) but still feels very solid, may need to file about .05mm-.1mm, something small like that off the hook parts so they fit really nicely, don't have heaps of printer time to test the fit properly. This new shell fits much better than the first iteration but you'll have to take the mid shell apart if you want to take it apart unlike the first.
I modeled this in fusion 360 based on 3d scans by u/Forty_0ne and a photogrammetry scan I took myself for good measure. The work in progress is up for now and I'll edit this text if I make any changes to it as there could always be something small or I figure I could have done something a better way down the line but I can say atm, it works for me.
Included is a copy of a shell with the bat ears that I only just thought of adding now so I haven't printed the whole shell to check the ears clear the scroll wheel but I did cut that part of the model off, printed that and held it up to see if it was a good fit and it looks good. As well as a copy with the top just flat which is what I did all my test prints with.
Print it in the orientation it's in for the best results and use supports where necessary. I use prusaslic3r which has a function called support enforcers which lets you resize objects that generate supports only within their area which is very handy for parts that have a million little holes in them so your slicer doesn't try to generate supports for every little overhang, you'll use less filament and have much faster print times and an easier clean up. I've included a reference picture of how I slice this for a consistent clean finish on the looking and feeling side of the shell and a quick google search will bring up a good video on support enforcers.
Note: the pegs don't align with their holes exactly which is something I can change if it's an issue for others. The cover doesn't wiggle at all if I try to move it around quite hard and I can actually take it off without having to unscrew the base by running a nail down under one edge and it pops off nicely all while feeling very sturdy when plugged in. So an error... maybe a feature in disguise!
Link to the plain version: https://www.thingiverse.com/thing:3945778