I was playing around with carbon fiber 3D printed cases in addition to the link cable work. The Onyx prints didn’t come out so well but the SLS HP PA12 prints are not bad. Still too expensive though at $24 per case.
The SLS prints also seem to mark up easily as well. Seems like the cart dust cover model here on PlanetVB may be too tight in dimensions. The SLS dust cover won’t go on the VB connector without pushing pretty hard. The cases are a bit tight as well. The plain case less so than the fully detailed one.
The plain covers print better than the fully detailed one with Nintendo writing on the back. The current models have the text too shallow for 3D prints. Virtual Boy shows up on the back using a 75um SLS print and an 100um FDM Onyx print but the smaller text at the bottom doesn’t show well with SLS and not at all with FDM Onyx.
I think the 3D models also have the screw depths too short or the screw on the back cover too deep as when you tighten the screws down they want to push through the front covers. You can see it in the pics of both the FDM Onyx and the SLS HP PA12 prints.
I’d like to try an SLA Formlabs Tough Resin print as well but they’re even more expensive than SLS. Seems like at this point donor carts are still the best option.
Here’s the final two assembled red test carts. It came out decent but it’s still not prime time. The material Durable is slightly flexible which isn’t ideal but it dyes well. I’d also probably suspend the part in the dye next time with some flow in the tank to get more uniformity. The material also warps slightly at the cart connector end.
These are ok for prototyping but I would not ship them to people as part of any project. It’s very close to being good enough but just not quite there. I’m going to try a few more materials and then probably table 3D printing cases and connectors.
I reprinted some Tough cases too. This material is probably the best so far. Too bad it comes in blue. It can be dyed a gray or black if needed and would make a decent non-donor case. It’s what Formlabs says is their “ABS-like” material.
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I also tested some High Temp material as well as dyed it RED. This material is stiffer than durable but way too brittle. The case cracked when I twisted it slightly. As a side note, the durable has gotten a little less flexible over the last day or two. I think the tough or durable material would be fine for people who want to print their own cases. Don’t think it would ever work for the connector. I’ll test Rigid and Grey Pro next. That will probably do it for 3D printing tests.
Rigid material prints nice cases. Definitely usable. Still not cheaper than a donor though at $8 in material just for the case.
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Here’s the final Grey Pro FormLabs test print. Comes out similar to Tough but grey. Not bad but for the cost I’d still just buy a donor.
I’m done with 3D printing testing for cases. If I go any further with any of this it will be with injection molding.
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My 3D printed cases are coming out much cleaner now.
