Brackets and mounts
510 Controller Enclosure (3x 18650, vertical PCB)
- Bounding box
- 41.4 × 52.9 × 84.4 mm
- Engine
- Precision B-rep
- Parameters
- 33
- Published
- October 30, 2026
Download
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The prompt
Design a premium ergonomic enclosure for a 510 soldering iron controller, using my uploaded PCB photos as references. PCB dimensions: 35 × 74 × 9 mm. The PCB stands vertically, with its front facing the flat front panel. Preserve its original layout: one black upper button, two white buttons horizontally aligned below the display, and a Micro-USB port mounted vertically on the PCB rear, facing the LEFT side when viewed from the front. Leave clearance for all rear components. Fit three standard 18650 batteries (18 × 65 mm nominal) vertically inside. All battery axes must be parallel to the PCB's 74 mm long axis. Arrange them in a triangular configuration: two batteries on the PCB side, the third on the opposite side. Create a smooth rounded ergonomic grip around the single-battery side. Include a top-center 510 connector mounting area. Keep the display face completely flat. Provide three independent external button-cap positions aligned with the original PCB switches. Create one editable parametric main enclosure body with internal PCB and battery clearance. Use 2–2.5 mm walls, rounded edges and approximately 0.3–0.5 mm general fit clearance. Calculate the external dimensions from the internal layout; do not guess them. Prioritize correct proportions, component clearance and industrial design. Export editable CAD and STEP/STL. This is a non-functional fit-check enclosure; do not design electrical or heating connections.
Parameters
| Name | Value | Range |
|---|---|---|
| Wall Thickness | 2.4 mm | 1.5 – 4 |
| General Fit Clearance | 0.4 mm | 0.1 – 1 |
| Display-to-Wall Gap | 0.4 mm | 0.1 – 2 |
| Rear Component Clearance | 3 mm | 0.5 – 10 |
| PCB End Clearance | 4 mm | 0.5 – 15 |
| Back Grip Corner Radius | 16 mm | 2 – 20 |
| Front Corner Radius | 3 mm | 0 – 10 |
| Top Rim Fillet | 1.4 mm | 0.2 – 3 |
| Bottom Rim Fillet | 1 mm | 0.2 – 2 |
| PCB Width | 35 mm | 10 – 80 |
| PCB Height (74 mm axis) | 74 mm | 20 – 150 |
| PCB Thickness | 9 mm | 2 – 30 |
| Battery Diameter | 18 mm | 10 – 26 |
| Battery Length | 65 mm | 30 – 90 |
| Battery-to-Battery Gap | 0.6 mm | 0 – 5 |
| Display Window Width | 24 mm | 5 – 40 |
| Display Window Height | 13 mm | 3 – 30 |
| Display Height Above PCB Bottom | 44 mm | 5 – 74 |
| Black Button Height Above PCB Bottom | 64 mm | 5 – 74 |
| White Buttons Height Above PCB Bottom | 22 mm | 2 – 74 |
| White Button Spacing | 14 mm | 4 – 30 |
| Button Hole Diameter | 6.2 mm | 2 – 15 |
| Button Cap Diameter | 5.8 mm | 2 – 15 |
| Button Cap Length | 3 mm | 1.5 – 6 |
| Button Cap Protrusion | 1.2 mm | 0 – 3 |
| 510 Recess Diameter | 22 mm | 8 – 34 |
| 510 Recess Depth | 1.5 mm | 0.3 – 3 |
| 510 Body Hole Diameter | 9.2 mm | 3 – 20 |
| 510 Centre From Front Face | 14 mm | 5 – 40 |
| Micro-USB Cutout Width | 9 mm | 4 – 16 |
| Micro-USB Cutout Height | 3.6 mm | 1.5 – 10 |
| Micro-USB Centre From Front Face | 13 mm | 5 – 40 |
| Micro-USB Height | 34 mm | 5 – 78 |
Every value above is a live dimension. Open a model like this in the editor and each one becomes a slider you can drag before exporting.
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