CNC Emergency Stop button station enclosure for 2020 aluminium profile

For my DIY Dremel CNC, I designed a compact enclosure for a 22mm Emergency Stop (ESTOP) button. It's designed to attach to the side of 2020, 2040, 2060, 2080, or 20100 aluminum profile extrusion beams, which are commonly used for linear rails or frame construction.

The enclosure measures 65mm square by 48mm deep, providing enough space for a standard 22mm button with a set of contacts. The walls and base are 2mm thick (requiring 5 wall loops for solid printing with a standard 0.4mm nozzle), and the cover is 4mm thick.

The enclosure is side-mounted to the profile using two M5x10mm screws and two M5 T-slot nuts within the profile's groove, which can be installed using ball-end Allen keys. I've added internal reinforcement around the M5 mounting screw holes.

A tongue is integrated into the side of the enclosure to match the 45deg angled upper half of the profile V slot so it can be printed without support, this allowing it to slide along the V-slot groove of the profile. The tongue is positioned so that the top edge of the enclosure (without the cover) is flush with the top surface of the aluminum profile.

The cover is secured with four M5x8mm screws and four M5 brass inserts in the enclosure body. The cover features counterbored holes for a clean look with cap screws. I've created two cover versions: one square, and one with a 4mm extension on the top edge, extending over the rail. This extension helps transfer some of the vertical pushing force directly to the profile through the cover, rather than solely through the two mounting screws.

I've also designed two enclosure variations: one without a pre-drilled wiring hole (allowing for custom hole placement), and one with a 16mm hole on the side facing the profile, designed for an M16 (or 5/8") wire strain relief. The hole is located in the lower half of the enclosure to ensure clearance from the aluminum profile (assuming the profile is mounted horizontally, not vertically).

Very sturdy and can withstand abuse, especially when mounted with the lower half against another profile (in the picture, it is against a perpendicular 2040 profile).