Dark Moth Enclosure R5

Dark Moth.
A considered case.

The original moth. A wired button on the side. A replaceable smoked face. Explore the complete prototype, down to the board, screws and wiring.

Explore the complete build Download print pack

R5 for the v3-button 12 V hand-build.
Digitally checked. First physical print pending.

Charcoal Dark Moth enclosure with the faceted moth engraved into its lid, a wired side button, and a smoked front panel.
Actual CAD geometry. Smoked material appearance is illustrative.
Case envelope
111 × 103 × 36 mm
Replaceable face
3 mm smoked acrylic
Button position
Left side detachable cable
Original moth
44 mm, engraved

Look closer.
Take it apart.

The case, populated PCB, modules, screws and harness in one model. Select a part to read its reference, or open the board guide for exact assembly steps.

Static assembled view of the complete prototype.

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All specified prototype assemblies are represented. The PCB comes from KiCad; modules, connector bodies and wire routes use labelled nominal geometry. The unpopulated PCB switch is not part of the build. Follow the component-by-component board guide →

Familiar character.
Better access.

The moth stays unmistakable. The details around it make the case easier to use and service.

A button where your thumb rests.

The left-side key presses a small tact switch in a captive carrier. A keyed two-pin pigtail lets you unplug the button from the main board.

A face that slides out.

Remove two front screws and lift the rail. The acrylic slides straight up; the electronics lid stays closed. No tape or glue holds the sheet.

The original Dark Moth.

The authentic 44-facet artwork returns as a 44 mm-wide, 0.5 mm-deep engraving. The fit coupon carries the same detail for a first-print check.

Direct top view showing the original moth engraving, uninterrupted moth lid and separate front diffuser rail.
The top faceAn uninterrupted moth lid and separate service rail.
Exploded CAD view of the lid, diffuser rail, smoked sheet and enclosure body.
The assemblyInspect the case, populated board, wiring and hardware together.
Complete internal assembly with PCB, battery, modules, side switch and wiring
Everything insideIndividual components and hardware, with their assembly positions.
Left side of the case showing the small side button
The side controlA wired, removable switch with a mechanically retained carrier.

Start small.
Print the coupon.

The body and button need supports. Check the setup and print the matching moth coupon first.

Open the print setup guide

Download the updated fit coupon

The default acrylic specimen

104 × 28 × 3 mm

Stock dimensions are unconfirmed. The earlier 94.8 mm-wide dark sheet is too narrow for this case. Measure your material before cutting.

  1. Check the actual sheet.

    The supplied files accept 3 mm smoked acrylic in a 3.4 mm channel. Use a deburred corner or small offcut in the coupon’s 3.2, 3.4 and 3.6 mm test slots.

  2. Inspect the first print.

    The updated coupon prints moth-down, just like the lid, with its slot banks up. Turn it over to check the fine facets and surface finish. Use the same plate, material and profile for the lid.

  3. Print the case parts.

    Start with black PETG, a 0.4 mm nozzle, 0.2 mm layers, four walls and 20% infill. The files already have their intended bed orientation.

    Body and button: enable normal automatic supports, turn “On build plate only” off, and turn “Don’t support bridges” off. Check actual supports in Preview. Fix the floating-cantilever warning →

  4. Build the board, then fit it.

    Follow the PCB assembly guide for exact component positions and wiring. Fit the side-button carrier before the boost module. Verify switch release, acrylic fit and operating temperature on the physical build.

    Open the case assembly guide

The files to make it.

Millimetres throughout. Editable source, portable models, real previews and the assembly instructions.

Complete print packSTLs, 3MF plates, source, guides and previewsZIP Black parts plateGeometry only · set body and button supports3MF

The portable 3MF files do not enable supports. Select your printer and filament, then follow the per-part print setup. The body and button require supports; keep the moth coupon face-down.

Bambu projects with supports saved: Body · P1S / PETG · Button · P1S / PETG. Reference: 0.4 mm nozzle, Textured PEI. Open as projects, select your actual printer and re-slice.

Individual print files

Acrylic envelope and source

The diffuser template describes purchased acrylic. Opaque black PETG would block the light. The complete pack includes all source dependencies.

Checked in the model.
Ready for a first print.

Digital checks support a careful first build. Physical fit, button feel, light quality and thermal behaviour remain to be tested with the actual components.

Geometry checks passed
344
Parameter-variant checks passed
547
Parts reference-sliced
7
Build the boardComponents, PCB positions and every connection Print setupSupport settings, orientation and all seven parts Printability reviewMeasured overhangs and first-print limits Verification recordWhat was checked and what remains