Ferris Sweep v2 Case

A PLA/PETG printable bottom case for the Ferris Sweep v2. The case is designed to accommodate one layer of 2mm thick foam that sits between the PCB and the bottom case. The foam slightly deepens/mutes the sound of the choc switches making it sound better compared to the sound on the bare PCB. The PCB is then screwed to the bottom case using the existing ‘tenting pucks’ screw holes.

Important: this case might not suit other versions of the sweep since different sweep versions may have different edge cuts.

BOM

For the full build you'll need the following items

• Foam with a 2mm thickness (needs to be cut to the size of the pcb)
• 6-8x M2 - 5mm Screws (6mm screws works if you dont tighten the screw all the way)
• Optional: Bumpons with a diameter of 8mm or 10mm

Building Instructions

1. Print the bottom cases: left half and right half
2. Cut your foam in the size of the pcb and cut holes in it where the screws of the tenting puck goes through. Use your PCB as a template to draw the outlines.
3. Place the foam in the case
4. Place the PCB on top of it and then screw it to the case using M2 - 5mm screws.

Tips: It's sufficent to use 3x screws to tighten the pcb to the case, since one of the screw holes of the tenting puck is hard to get to with the choc switch being in the way.

Variants

There are several .stl files of the case, so choose the one that suits you.

• Case with 8mm Ø Bumpons
• Case with 10mm Ø Bumpons
• Case with no Bumpons

On top of that: I made small cutouts on the sides of the inner case wall to allow some “uncleany broken” FR4 to stick out where the PCB had to be split. 

Depending on the iteration of the Sweep v2 the break out points are either on…

• … the inner side where the pro micro is located (use .stl file with the “inner” tag) or
• … the outter side (use .stl file with the “outter” tag)

Example of the PCB breakout being placed on the outter columns of the PCB.

Example of the PCB breakout being placed on the inner columns of the PCB.

Technical Details

• Case Height: 7mm
• Case Length: 114.7 mm
• Case Width: 94.2mm
• Wall Thickness: 3.6mm
• Bottom Thickness: 2.4mm

Print Settings

• Infill: 15-20% Gyroid
• Perimeters: 2 (can also do 3)
• Layer height: 0.2mm
• Supports: none