i3 prusa PSU safety cover with mains socket / fuse /switch

thingiverse

This is very safe cover for the PSU (see screenshot and 1 cutaway to see internal compartments of this cover). But first a notice. I made silly mistake when printing and instead of rotating the part before printing I flipped it, this caused it to be mirrored. The socket is designed to be in the far end corner I just printed it badly. I might reprint it one day. you can't touch the connectors even when you try to (the bottom is concealed) is small and is not sticking out nor is square (there is not edge on bottom to hit by accident), in case you will tilt the printer there is lot of clearance so this cover will not get abused / damaged when you will move the printer around the mains socket is physically separated in it's own compartment. if any wire will get lose, it will not touch the PSU connector (it's protecting against the case the live could touch the + DC terminals) mains socket is touching the PLA barier and the PLA barrier is touching the outer PSU case. meaning there is no give when somebody tries to yank the power cable. Still I wouldn't recommend it but it is firm against the case + it's insulated from CASE or the connectors. the PSU has cover for the connectors, when this cover is on the PSU, it's physically impossible to open this cover (you can't reach it by hand, but even vibrations will not open it because this case is in it's way). small notches will keep the mains socket secured tripping over the power lead should detach from the socket without damaging anything and without stressing the connectors in the PSU in worst case where the force is strong enough to yank and damage the case, still you are protected by the physical separation of the compartments etc... It's plastic so if you want you can destroy / damage it, but I think I made the most I could and from all possible issues I could encounter this cover is covered (pun intended) has space for second compartment and a hole for switch (there is version without the hole), this is for future upgrades, I'm working on software OFF feature where PSU can be turned off after print is done and the switch can enable / disable this feature. There is hole on the top to access the the second compartment. This hole is then against solid metal when the cover is on and is 90 degree away from to connectors so it's safe to have access hole on the top. the wires even when they get lose will not move around the compartments. The wires from mains compartment need to pass to the second compartment and then to the bottom hole to get out of the case (see the cut screenshot to see bisected inner compartments). Because the wires are physically constraint I hope the vibrations while printing will have very little effect on the connections in the long term. It feels to me as pretty solid / rigid cover. even it has lot of material around to make good and strong fit around the case, it still doesn't block the front venting holes It's designed to be used with this mains socket: http://www.ebay.ie/itm/IEC-Mains-Male-Female-Connector-Entry-Module-Fuse-EMI-Filter-Switch-/231966537139 I have filament fan, so I was able to print everything like this without any support, you need to rotate the object by 180 around X axis before printing. Used 0.3mm layer height and with 3 bottom and 3 top solid layers. The infill can be anything, even 100% will not make much difference because with these settings there is probably only single layer where it makes difference. Lot of the model are just perimeters or solid bottom / top layers. The pass-through holes for the cables create small bridges first and they are closed first and then the top cover is printed, so I made few arrangement to allow decent printing without support structures.