This was my first major personal challenge/hell with 3D modeling to spec. The specifications were to be no larger than 4"x5"x4". I chose to maximize and those are the exact dimensions of this case. It needed to house 2 large batteries, a PCB, fan, and a Jetson Nano. Luckily, NVIDIA supplies .stp files of their Jetsons so using one in my modeling process was a bit easier than not having it.

The case also needed to be windshield attachable and therefore able to hold up around 5 lbs. I remembered an old phone holder I had for my car that I never used the windshield attachment for. I dug it up and studied it. I reverse engineered the suction cup mechanism to fit into my enclosure design. I also roughly matched the angle of my windshield to the front-top half of the case so it would rest flush and be less of a visual obstruction.

I dug it up and studied it.

I love my calipers. I can make just about anything to spec with that wonderful tool. I started out with a solid block in the software and hollowed out and cut to match the angle of the windshield. The battery compartment has a cutout in the floor for a tiny bit of added space. I also cut a little nick out of the inside top for the fan to fit.

The more complex the piece the more I would suggest saving 2 versions.

As you can see some of my objects have shifted around inexplicably since I first made the case. I recommend copying the project file and saving a version that's completely rendered up to the point of current progress. Have the old on file if you need to make major past edits but save the processor from sifting through that long timeline.

Everything fit, except for the battery

I forgot to account for the ends of the header pins from the PCB that would be hanging down into the battery tray. This millimeter or so was enough to damage the battery if it were forced in. However, the inner shelving for the boards fit perfectly. The front end camera screwed into the front face as planned. The door closed AND, most importantly, the suction cup mechanism worked.

The suction cup is jointed with the lever on the right side. When turned toward the driver, the tension on the suction cup increases by pulling back the spring-loaded suction cup ever so slightly for maximum adhesion.