DIY Modular Anderson PowerPole distribution box - 3D printed

nikdfish said:

I just finished up a new version of components to build a 3D printed Anderson PowerPole distribution box. It differs from the previous versions I've done in that it has a flat profile and is modular. The basic housing framework has slots for "modules". There are modules for holding powerpole pairs, fuses (standard automotive) and blank placeholders. Customized versions can be assemblled that include fuses for some, all or none of the circuits. The housings can be either single sided or double sided. Once modules are in place in the slots, a slide lid is used to secure things in place. It can be secured with glue if desired.

Pics of a 4 slot, single sided assembly:
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Now pics of a double sided, 4 slot housing:

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I put files on Printables for 4 & 6 slot, single & double sided versions. I also included the Fusion 360 source file. The Fusion 360 source file was parameterized so that changing the "circuit_n" parameter automaticly adjusts the single & double sided versions to include the specified number of slots per side and adjusts all related components to fit.
https://www.printables.com/model/816564-anderson-powerpole-modular-flat-distribution-box

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nikdfish said:

Printers currently range from sub $200 on up. Cheaper ones will probably take some tweaking to get decent results. They print lower temp materials like PLA well enough but typically don't handle high temp materials very well. Decent consumer equipment with less need for tweaking can be found in the +/- $400 range, with price varying with features offered.

I like using ASA filament for prints as it handles higher environmental temps & UV better than most other materials. It does take an all metal hotend (for higher print temps), a high temp bed (>= 90c) & an enclosure of some type (to help mitigate warping) to print reliably.

I did it initially with a modified, old style, Ender 3 in a homemade enclosure. I now print ASA using a Qidi Xmax3, which has a heated enclosure & high temp bed. It also prints 3 or 4 times faster than the Ender 3.

Materials cost, without hardware, for the larger (double sided) example shown is about 52g of filament. At $25/kg, that's about $1.30 in filament. (BTW, $20-25/kg is cheap for ASA, $30-35 is common) There is some electrical cost, figure 300 watts (aprx.) for two hours. The biggest piece of the cost to build are the anderson powerpole components at ~$1 or so per pair plus quick connects and wire.

PLA and PETG filament material is typically a bit cheaper than ASA with some brands as low as $15 or so.

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