Handheld Gas Sensor Enclosure (Exploded)

Design a fully parametric 3D CAD model of a handheld gas sensor enclosure with a cubical body. The enclosure must consist of three separate components: a hollow front cone, a square mounting plate, and a hollow cubical body. The main body should have a square cross-section instead of a cylindrical one. The body dimensions should be approximately 50mm × 50mm externally with a length of 100 mm. The wall thickness should be 2.5 mm. The rear end should remain open to allow PCB insertion, while the front end should accept the square mounting plate. Apply small fillets or chamfers to all outer edges. Inside the cubical body, create two continuous guide rails along the full length to allow a PCB to slide in and out smoothly. The rails should securely hold a standard 1.6 mm thick PCB with approximately 0.3 mm clearance on each side. The PCB should stop approximately 15 mm before the front plate. Create a square mounting plate measuring 50 mm × 50 mm with a thickness of 3 mm. The plate should fit flush into the front opening of the cubical body and be secured using four M3 screws located at each corner. At the center of the plate, create a cylindrical threaded boss with external (male) threads. The threaded boss should extend approximately 12 mm from the plate and include proper lead-in chamfers for smooth assembly. The threads should also be hollow for the air to pass through it. Create a hollow conical front nose that screws onto the threaded boss. The cone should be approximately 35 mm long with a base diameter matching the threaded boss and a tip opening of approximately 2 mm for air intake. The cone must contain internal (female) threads matching the external threads on the mounting plate. When fully tightened, the threaded joint should be hidden inside the cone so that no threads are visible externally. The air path should begin at the small opening at the tip of the cone, travel through the hollow interior of the cone, pass through the central opening of the mounting plate, and continue directly into the cubical enclosure toward the sensor mounted on the PCB. The square mounting plate should remain permanently attached to the cubical body using four screws, while only the cone should be removable for servicing. The PCB should be removable from the rear without removing the cone assembly. Design all mating parts with approximately 0.25 mm to 0.35 mm clearance for smooth 3D printing. Avoid unsupported overhangs greater than 45 degrees. Reinforce the threaded boss with fillets for improved strength. Generate the complete assembly, exploded assembly, sectional views, and separate CAD bodies for: 1. Cubical body 2. Square mounting plate 3. Hollow threaded cone Output the design as a fully parametric CAD model compatible with Fusion 360 and export STEP and STL files.

Parameters

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.