Thermostat Enclosure

Populated PCB, display, CO₂ sensor, push-turn knob: the university had built the entire electronics for the lecture-hall thermostat itself, and none of it had anywhere to sit yet. A lecture hall is public space, so the enclosure had to stay serviceable while stopping anyone from opening the control on their way past, built on the machines the university already had.

Lid, four latch holders and the flexible latch merged into one SLS part, six pieces down to one, printed in place with a 0.3 mm gap. The latch still springs even printed; what's still open is how many cycles it takes before it doesn't. Seven major revisions sit in between, plus around a hundred small ones, each triggered by a specific problem with the last: strain relief, screw countersinks, hole sizes, and enough height for a sensor soldered on late.

The final revision became an installed series that's been running in the lecture hall since it went in, shown here in the design state it was actually built from.