The aim of this project is to manufacture a stylish and fully programmable desktop companion by blending together modern electronics and a custom laser-cut wooden enclosure.
DetailsThe device is based on Adafruit's Feather Huzzah esp8266 and the 2.4" TFT Feather Wing. The enclosure is desigen using Fusion360 and cut out of birchwood using a 140W laser.
This whole project is based on adafruit's guide which you can find here https://learn.adafruit.com/adafruit-feather-huzzah-esp8266/using-arduino-ide, my only improvement beign the wooden enclosure.
The process1.Sketching
This step is rather crucial and it implies a few minutes in which im trying to decide what I will do and envision how the final product will look( mind you, more often than not the final product looks nothing like the starting idea but without this step, no idea will be able to materialize).
2. Measure the "guts" of the device
In this case, I have measured all the needed dimensions of the electronic system used
3. Create a rough 3D model of the electronics so you can base the enclosure design around that
4. Create the 3D model of the enclosure using sheet metal (it allows unfolding) and export it as.dxf
5. Create a rounded box using Boxes.py(a free tool - https://festi.info/boxes.py/FlexBox?language=en) and use the lattice hinges generated by this piece of software in your design. In the past, I have used to unfold all the bends of my design, generate the lattice hinges manually, extrude them as surface, thicken it and extract it from the target body ( it usually ends with fusion360 crashing) but now I am wiser and I simply add them in my go-to vector manipulation software (see? I have just saved you a few good hours)
6. Use any vector manipulation software like Inkscape(free) or Adobe Illustrator(paid) to add lattice hinges to your design and get it ready for laser-cutting.
Build instructionsStep 1 - Program the ESP8266 usingFthe instructions provided by Adafruit
The instructions may be found at https://learn.adafruit.com/adafruit-feather-huzzah-esp8266/using-arduino-ide followed by https://learn.adafruit.com/wifi-weather-station-with-tft-display/overview?view=all. Remember to download the libraries using only the links provided on the website instead of manually searching for them in the Arduino IDE ( some names have been changed and this can lead to errors).
Ensure that the settings.h file is in the same folder as esp8266-weather-station-color.ino and configure your SSID and Password. After all this is done, head to https://openweathermap.org/ , create a free account and generate your API key that you will insert in the "OpenWeatherMap Settings" section of the settings.h file. Now just plug in your ESP8266, wait for it to connect to WiFi ( I had to reboot it around 3 times before it finally connected), follow the instructions displayed on the screen and you should be good to go.
Step 2 - Download the DXF made available in this project
Step 3 - Cut the enclosure from the desired material of 3.6mm-4mm thickness
In my case, I have used "4mm birchwood" that was actually 3.6mm thick after a careful measurement.
Step 4 - Fix the screen using self-drilling screws and assemble the enclosure using glue if necessary
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