If I were using the sled...I would mock up up or down wire flow and see if there was room for a below routing plan. If you are a meticulous person, then you will want it clean. Personally I go for "serviceable" which would be an above routing so I could tweak any post build issues.
I have printed a number of things from the three major commercial 3d printing houses, but in the end I never felt the resulting mods had the feel I wanted. I may try again now that they have better metal selections, but the accuracy of the metal printing is a bit frightening vs the lost wax...
I have only build regulated, but I could see myself venturing into unregulated with that chip...it is available? It would be great inside a more custom enclosure.
Very clean...what is the schematic layout of the front bezel you have designed...i.e. are those holes for onboard button use or off-board? I have tried custom printing buttons, but the process was so iterative to get things right that I gave up.
Thanks! I am still bummed that the burl is so thick that I have had to cut out room for the charging cable housing, but I am working on a bezel that will solve that. Soldering with tweezers is not my thing! I am still thinking this is a prototype as the first brazing of the aluminum was...
I posted a few more pics in woodcraft...but here is where one of the DNA40s ended up. Still working on a bezel for the charge port.
No room left on the inside:
Trying to get the form factor down even further. I still need a bezel for the charger...but that is another day. My only advice is don't try this! Not nearly enough room.
General specs: Large screen DNA40, lexan cover, aluminum frame with dye stabilized burl skins.
What is listed as unresolved? All of the issues I have been aware of are resolved, but I may be out of the loop. The current large screen version seems solid.
I have also had success with painter's tape as a scuff layer then using normal press fit tools. That said, I have little patience for press fit crap (other than bearings) as it is usually indicative of disposable junk.
If I were you, I would go down to the local big box store (blue or orange if you are in the US) and get some aluminum and just make a plate larger than your goofed up hole, and cut an appropriate hole in it, then simply epoxy it on.
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