Ender 5 rear control box with Pi, SKR Mini, SSR, Buck Converter, CSI-HDMI mount - 200 x 200
Description
This printer has tons of potential, but the terrible cable management and lack of decent control hardware made me eager to try my hand at a better control box.
I wasn't satisfied with any of the Ender 5 control boxes I found. They were either too big to print on the Ender 5 bed, didn't have mounts for the various components, or relied on serious modifications to the printer itself. They often left wires exposed - especially on the power supply! And, many of them didn't address the cable management issue or relied on other designs to make them work.
I started from scratch and designed everything here myself. I've been working on this for about 6 months now. I'm excited to release it!
I've included plenty of pictures and 3D renders to help you see how to put it together. Let me know if you need close-ups of anything or more details.
I used rubber grommets in some of the cable management holes but this is really your preference. If you want to use them, they are 3/4 inch grommets.
If you try this and like it, please post a make! This encourages me to keep going with these kinds of projects.
One last thing: the pictures are of the previous version, but the STL files are the latest version. In the newest version, the power switch has been moved and the CSI-HDMI converter now has a mounting location. Enjoy!
Design goals
* use the maximum number of original parts
* good airflow using the original fan
* make cable management easier
* be flexible enough to expand with a raspberry pi, CSI-HDMI converter for the Arducam, buck converter
* provide access to all ports on the Pi and SKR mini board
* limit the need for supports
* don't reduce print height
* use easy-to-source parts on Amazon
* small enough to print on the existing print bed
* provide safety by keeping power parts on one side and data parts on the other
Parts used
In this list, I've provided Amazon links to the parts I actually ordered and used. You can use similar parts from any manufacturer. Just be sure the hole patterns match so they will properly mount in the box.
Major components
* Raspberry pi 3, 3B+, or 4
*Other Pis SHOULD fit because they have the screw pattern and I made the holes in the side large enough to expose all the ports
* BigTreeTech SKR Mini E3 V3.0
*https://www.amazon.com/dp/B09LC34SCK?ref_=ppx_hzsearch_conn_dt_b_fed_asin_title_13
* original case fan, power supply, lcd display (optional), and some of the wires
* 25ft - 1/2 inch Cord Protector Wire Loom Tubing Cable Sleeve Split Sleeving For USB Cable Power Cord Audio Video Cable
* https://www.amazon.com/dp/B07FXF12HC?ref_=ppx_hzsearch_conn_dt_b_fed_asin_title_1&th=1
* Power Converter Regulator DC 12V 24V to 5V 5A 25W Regulated Power Supply Step Down Module Transformer
* Power Converter Regulator DC 12V 24V to 5V 5A 25W Regulated Power Supply Step Down Module Transformer
* https://www.amazon.com/dp/B09VY41QBF?ref_=ppx_hzsearch_conn_dt_b_fed_asin_title_1&th=1
* I used this to power the Raspberry Pi via the GPIO pins. Yes, I know it's not recommended. You should probably put in a polyfuse or something.
* Yes, I know people want to complain that this buck converter isn't fancy enough for the Raspberry Pi's needs. I assure you it has been working just fine for months and plenty of long prints
* Solid State Relay SSR-25DA DC to AC Input 3-32VDC to Output 24-480VAC 25A Single Phase Plastic Cover
* https://www.amazon.com/dp/B08GPJ1V2J?ref_=ppx_hzsearch_conn_dt_b_fed_asin_title_3&th=1
* CSI-to-HDMI Adapter Set for Raspberry Pi Cameras (Pack of 2, 1 Set)
* You only need this if you're using a raspberry pi cam or Arducam and you want to use an HDMI cable to connect it to the Raspberry pi.
Electrical connections
* 22 Gauge Flexible 2 Conductor Parallel Silicone Wire Spool Red Black High Resistant 200 deg C 600V
* https://www.amazon.com/dp/B077XBWX8V?ref_=ppx_hzsearch_conn_dt_b_fed_asin_title_6&th=1
* for data connections
* 16 Gauge Flexible 2 Conductor Parallel Silicone Wire Spool Red Black High Resistant 200 deg C 600V for Single Color LED Strip Extension Cable Cord,Model,25ft Stranded
* https://www.amazon.com/dp/B077B5HFXN?ref_=ppx_hzsearch_conn_dt_b_fed_asin_title_23&th=1
* For power connections
* Crimp Connectors, 2.8mm 4.8mm 6.3mm Male and Female Spade Connector kit
* https://www.amazon.com/dp/B0B4H54KPS?ref_=ppx_hzsearch_conn_dt_b_fed_asin_title_9&th=1
* Flat Ribbon Cable 2PCS 2.54mm Pitch 2 Row 10 Pin Female to Female Wires IDC Ribbon Connector 1m/ 3.3Ft
* https://www.amazon.com/dp/B09VX1SM12?ref_=ppx_hzsearch_conn_dt_b_fed_asin_title_8
* To connect to the LCD display
* XH 2.54mm Connector Kit - JST XH Compatible 2.5mm Pitch Male Female Connector Sockets Plugs and 22AWG Pre-Crimped Silicone Cables Wire 2 3 4 5 6 Pin Housing
* https://www.amazon.com/dp/B0CM315RFP?ref_=ppx_hzsearch_conn_dt_b_fed_asin_title_21
* Dupont Crimping Tool Kit Ratcheting Wire Crimper with 2.54mm 600PCS Dupont Connectors and 560PCS JST XH Connectors,Dupont Crimper,JST Crimper(0.08-0.5mm² 28-20AWG)
* https://www.amazon.com/dp/B0C6PM9KGY?ref_=ppx_hzsearch_conn_dt_b_fed_asin_title_14&th=1
Hardware
*Screws Bolts and Nuts Assortment Kit, M2 M3 M4 M5 Nut Bolt Assortment with Lock & Flat Washers
* T Nuts M3/ M4/ M5
*https://www.amazon.com/dp/B01NAGBBNT?ref_=ppx_hzsearch_conn_dt_b_fed_asin_title_7
Special skills needed
* make JST crimp connections
* make spade crimp connections