Redesign of 3D Printable Electronics Enclosure

Redesign of 3D Printable Electronics Enclosure (SolidWorks) Project Overview I have designed an enclosure for a door/window contact sensor. The enclosure is mostly complete, but I need an experienced SolidWorks mechanical designer to redesign and optimize the battery door and latch mechanism while improving the overall design for FDM 3D printing. The enclosure will be manufactured on an Anycubic Kobra 3 V2 using a 0.4 mm nozzle and primarily printed in PLA (with possible future PETG use). This is not a request to create a new product from scratch. The existing CAD files, assembly, and reference photos are provided. The goal is to improve the current design. ## Current Issues * Battery door latch is difficult to print reliably. * Current latch is weak and can break during printing or support removal. * Some visible surfaces require supports, leaving unacceptable cosmetic defects. * I want the enclosure optimized specifically for FDM printing without sacrificing appearance. --- ## Design Goals The redesigned enclosure should: * Keep the same overall appearance as the reference photos. * Maintain the sliding battery door concept if possible. * Redesign the latch mechanism if necessary for improved strength and reliability. * Minimize or eliminate supports on visible surfaces. * Print cleanly using a standard 0.4 mm nozzle. * Be durable enough for repeated battery changes. * Be easy to assemble. * Keep the electronics layout unchanged unless absolutely necessary. --- ## Deliverables Please provide: * Native SolidWorks Part files (.SLDPRT) * Native SolidWorks Assembly (.SLDASM) * STEP files * STL files ready for printing The SolidWorks files must remain fully editable with a clean feature tree. --- ## Requirements The design **must** be optimized for FDM printing. If the enclosure cannot be printed cleanly with minimal post-processing on an Anycubic Kobra 3 V2, then the design does not meet the project requirements. I prefer a practical design that prints reliably over a design that only looks good in CAD. --- ## Files I have * Existing SolidWorks parts * Existing SolidWorks assembly * Reference product photos * Photos of current printed prototypes * Photos showing the current latch issues * Photos showing cosmetic defects caused by supports --- ## Future Manufacturing While the immediate goal is FDM printing, it is a plus if the design also follows good practices for future injection molding. --- Please review the current design and improve it rather than starting over. If you believe a different latch mechanism would produce a better result while maintaining the overall appearance, I am open to your recommendations