Make Custom Protection: Your DIY Guide 3D Printing Pelican Style Box
The Pelicans case’s ruggedness and reliability are legendary, blocking everything from camera gear to medical devices. But what if you need a case tailored to exception shapes, then the ready-made option won’t meet? Enter 3D Print. By combining accessible printing technology with smart design, Diyers can now create customized protection cases that rival customizable commercial solutions. This is how to initiate this integration of creativity and engineering.
Why 3D prints a Pelican-style case?
- Super destined: Perfectly outline your box to fit irregular tool, prototype or hybrid device loads.
- Cost-efficiency: Avoid overspending on oversized prefabricated cases or complex custom orders.
- Quick iteration: Prototypes are designed quickly without tool constraints.
- Integrated features: Embed the battery, cable or sensor holder directly into the structure.
Design points: Blueprint for success
Start with CAD software (Fusion 360, Tinkercad). Main things to note:
- Shell structure: Ribbed model wall for rigidity. Pelican case uses a double wall design – send it out with 3-5mm exterior wall + internal webbing.
- Closed system: Combines the tongue edge and embedded washer passage. Standard foam strips or O-rings ensure water resistance.
- Hardware integration: Design the mounting points for latch, hinge and pressure valves (available as standard components). Expert tip: Print latch in flexible TPU to absorb shock absorption.
- Modular interior: Beyond the bubble. Print lattice inserts for exquisite items for tools or compression pod holders.
Material Important: Choose the right thin silk
- asa – UV/weather resistance and high impact strength: Very suitable for outdoor applications (such as drone cases).
- Petg – Tough, moisture-proof and food safety: Great for medical equipment or kitchen technology.
- Nylon (PA6/66) – Protect the excellent toughness of heavy equipment. A closed printer is required.
- TPU – Used for seals, gaskets or flexible components (such as pad grips).
When plastic is not enough
For critical hardware (paragraphs, hinges or structural installations, subject to extreme forces), plastic should be replaced. For machining components, Great CNC-MILD aluminum or stainless steel parts are available. Need complex geometric shapes? Their SLM Metal 3D Printer Available in durable titanium or hardened steel inserts for professional-grade versions.
Printing workflow: Durability tips
- direction: Print flat sides for optimal layer adhesion at high pressure points.
- Wall settings: ≥4 surrounding + 30–50% capable of anti-torsion thyroid filler.
- water proof: Apply epoxy resin or silicone-based sealant to the layer line. Test the immersion depth of 1 m.
- Grinding/starting: Smooth the surface with 400-grain sandpaper, then spray paint with urethane for splash-proof effect.
Assembly: Put it together
- Sealing gaskets are sealed using marine grade silicone adhesive.
- Connect the hardware to the stainless steel threaded insert (hot-set in the printing hole).
- The hinges for load testing exceed gears for stability.
When to go to professional: Improve performance
Although the FDM printed cases are suitable for moderate demand, loads of ~15 pounds or high impact environments are worth professionally manufactured. Greglight’s industrial solutions Glow here:
- SLM Metal Printing:Produced entire housing in aluminum alloy for fire-resistant/flight-resistant applications.
- Hybrid prototype: Combine plastic body panels with aluminum frames produced by CNC to enhance stiffness.
- Post-processing: Anode, bead blasting or powder coating to resist weather/wear.
Real-world use
The drone operator created a box with a PETG panel and a Greatlight Prinps aluminum hinge rack. result? Lighter than the Pelican IM2100, the hinge life is 200% higher.
in conclusion
3D printing democratizes rugged case manufacturing – blending flexibility, speed and creativity for enthusiasts. For most DIY projects, filament-based printing has achieved a successful balance. But when longevity or strong demand is imminent, metal components are integrated into professional assets through partners like Greatlight Trundition. Whether it’s a prototype one-time or engineering deployable solution, the future of custom protection is in your hands as well as the printer.
FAQ
1. Can 3D printed boxes be truly waterproof?
Yes. Get IP67 ratings by
- Use watertight printing (100% extrusion width).
- Seam the seams with silicone compound.
- Insert rubber washer. Built after testing in a bathtub!
2. How much weight can a plastic box bear?
PETG/ASA cases safely carry about 10–15 pounds of walls/40% fill. For heavier loads:
- Use inner ribs to strengthen the high stress area.
- Use metal corner brackets.
- Printed with nylon carbon fiber composite.
3. Is printing cases cost-effective and buying a Pelican?
For standard sizes (e.g. 12"x10"), the Pelicans are cheaper. DIY wins:
- Non-rectangular shape.
- Integrated components (such as IoT mounts).
- Run 5 units.
4. Can I print large boxes on a small printer?
Divide the design into CNC-style finger joints and other puzzle joints. Combine with acetone (ABS) or epoxy and reinforce on the outside with fiberglass tape.
5. Why consider metal parts from Greatlight?
For key hardware:
- strength: Titanium latches are affected by plastics.
- accurate: ±0.1mm CNC tolerance ensures a perfect seal.
- scale: Very suitable for batch production after prototyping verification.
About Greatlime
When your DIY project requires professional rigorousness, Great Delivery – Fusion of fast SLM metal 3D printing, CNC machining and expert post-processing. From drone parts holders to aerospace homes, we transformed prototypes into unyielding production-grade solutions. Customize the metal components of the project now.
Transform elasticity into reality – hierarchy.
