Netgear Hotspot Case (MR6110) - Nighthawk M6

About this model:

This has been modeled for the Netgear Nighthawk M6 (MR6110)

It is a simple snap fit outer case, made from PLA, PETG, or whatever filament you like. There is an inner “sleeve” designed for TPU. I mimicked basic phone case designs.

There is a charge port open at the base. Because we use this model as a mobile hotspot, moved from job to job in work bags, I did not include a hole for the cat6 port or the aux antenna ports below.

The top power button has an extension integrated into the TPU sleeve so larger fingers can easily press the power button.

The original model I printed (pictured above) has company logos. The files uploaded are generic (no logos). There are multiple bottom case options, one with the vent holes I designed and another with no vent holes if you'd like to make your own. Vent holes may not be needed, but the unit can get pretty hot in bags and I wanted to be sure it could cool down easily.

Customizable:

I have included step files to make it easy to import and edit in the CAD program of your liking. Please upload makes and pictures any one-off custom cases you may print, I'd love to see other versions I may not have thought to design!

Printing:

It is best to print the top and bottom faces on the build plate (the logical print orientation). The latching tabs on the top cover are designed with supports built in to be printed with the top cover on the build plate.

The PLA parts (top and bottom case pieces) have been designed with a .25mm clearance, which should help the parts fit when printed with most FDM printers. I have included a test box using the same clearance and latch parameters as the main model. I would definitely suggest testing before investing time and filament to find out something doesn't work right. The TPU gasket is designed to add some tension when the lid is latched. If it is too tight, or too loosely latched, you can scale the gasket's z-height in your slicer for quick adjustment. The locking tabs aren't very robust, however, so too tight may result in breakage.

Supports are not needed for the outer PLA covers. You will likely see a warning about floating regions or cantilevers, but that is because the built in support is .2mm off of the surface to make it easier to break away when you first snap the covers together.

Supports are likely needed for the bottom TPU sleeve. TPU doesn't general bridge well for me so added supports will help reduce cleanup later. The slicer generated “normal” supports worked just fine on my well tuned TPU profile.

Other Random info:

Some dimensions used (may be useful to see if this will work with other model hotspots / netgear devices):

Netgear Nighthawk hotspot Dimensions:

Height: 21.75mm,
Width: 105mm square, 
Corner radius: 18mm, 
Screen width: 50mm, height: 38mm

Tolerances used/ built into model:

TPU inner sleeve to outer bottom cover: 0.25mm
Top latching lid to outer bottom cover: 0.25mm

Gaps around side latching tabs: 0.4mm

TPU sleeve thickness: 1.5mm
TPU gasket (goes between lid and hotspot): .8mm
Outer case thickness: 2mm

Congrats if you made it to the bottom of this! Happy printing