520ST PSU Remake

[exxos]

Interesting. For me the bottom section was estimated at 5h 43 with 20% infill at .3mm. Top was 6 hours exactly. I can't remember travel times and print speeds off the top of my head.

@ .2mm both were 7 hours +.

I should be able to add a pic of the top sometime tonight.

0.3mm layers gives me 3hours 3mins.

0.2mm 4H 17mins.

0.12 (my default currently) 6H 38mins.

So I may try 0.2mm on my boxes next...

[rubber_jonnie]

As promised, here is the top of the case:

IMG_20190419_090514.jpg

Next is cleanup and final assembly.

[exxos]

Looking nice!

[PhilC]

Looks great RJ. How long dud it take to design it?

[rubber_jonnie]

And some more pics.

Top and bottom together:

IMG_20190419_092406.jpg

And the two parts fit together very nicely :)

IMG_20190419_092355.jpg

The top half still requires the vent holes and 'flash' to be cleaned up.

I know 'flash' is typically a term used for injection moulding, but it looks very similar to the brim of a 3d print.

[rubber_jonnie]

Looks great RJ. How long dud it take to design it?

I'll be honest Phil, I can't take credit for the design, through discussions with various other people I was directed to it on Thingiverse, there is a link early on in the article.

It was designed specifically for the PSU I was using (or its variants), by someone replacing an Amiga PSU.

Thought it would be silly to try and reinvent the wheel.

[Icky]

:coolpics: Nice

[PhilC]

Makes total sense to me RJ. And looks like it will clean up nicely.

[rubber_jonnie]

Hmm, suspect my change to .3mm has had a side effect in that the top vents are really hard to clean the support structure out of.

Still, you live and learn, this is probably the largest most complex piece I've yet printed, so first go was always going to be a try out.

It is cleaning up ok, just taking longer than planned.

[rubber_jonnie]

OK, so it's finished and happily powering my 520ST 😁

IMG_20190420_152034.jpg

IMG_20190420_154511.jpg

IMG_20190420_154529.jpg

Project over, what would I say are the gotchas?

Well, in all honesty, the worst part was the top half of the case.

My decision to print @ .3mm bit me down the line, as the resolution was too poor to do a good job of the case vents, leading to a lot of filing and picking away support structures that simply weren't fine enough.

It's also possible that another material, such as ABS may be a better choice when printing.

What I gained in a faster print speed, I lost in tweaking the case to clear the air vents.

Other than that, it was a pretty simple process.

I hope this gives someone the confidence to have a go when they need to replace a PSU that is not a common item any more.

As an aside, this same PSU can be used to replace an Amiga unit, as was done by the original designer of the case itself.