PyBadge Protective Case with D-pad

3D-printable PyBadge Case

The Adafruit PyBadge and PyBadge LC are compact development boards that include a 1.8" display, eight pushbuttons, and a built-in mini speaker, designed to resemble a handheld gaming device.

These boards support CircuitPython programming, enabling users to create and play custom games that utilize these hardware features.

This project showcases the PyBadge Case, a 3D-printable case designed to help protect these exposed boards during use, while giving them a traditional handheld look and feel.

The design of the PyBadge Case features:

• D-pad Button: A raised d-pad allows for better thumb interaction with the board's four directional input buttons
• Compact Size: Case size is optimized to tightly enclose the board and battery/speaker, with minimal wall thickness to reduce its size
• Cushioned Buttons: Printed soft spacers are placed below each printed button for a softer, tactile press and reduced clicking noise
• Reduced Button Play: Tight print tolerances in the button openings and spacer gaps reduce button wiggle for a more solid feel
• Easy Install: The two case halves fit around the PyBadge board, fastened together using M3 screws to secure it in place
• Custom Colors: Case components (front, back, buttons) can be printed in various colors to create a customized appearance

Visit the GitHub repository for the PyBadge Case to access the printable STL files for each case component, and its Fusion360 project file which can be used to modify the components.

3D Printing

Using the provided STL files, the case components can be 3D printed with standard settings and materials.

Two material types are recommended for the finished case - PLA for the rigid components (case, buttons) to provide protection and structural integrity, and TPU for the spacers to deliver softer button preses.

The following printer settings are recommended:

• Materials: PLA: Case front and back, D-pad, single buttons (2x), button pair; TPU: D-pad spacer, single button spacer (2x), button pair spacer
• Layer Height: 0.2mm
• Infill: 20%
• Supports: Not required

Assembly

With the components printed, the case can be assembled and enclosed around a PyBadge and its connected LiPo battery. This build uses a PyBagde LC, and does not include an optional connected speaker.

Begin by inserting the buttons and d-pad through the face of the case, ensuring that the base of each button is seated within its button pocket. Next, add the soft spacers on top of the buttons and d-pad, also within the pockets.

Connect the battery to the PyBadge LC, then place the PyBadge LC face down on the case front, aligning the PCB mounting holes with the corresponding mounting points in the case.

Finally, place the case back on top of the PyBadge LC, and use the four M3x10 screws to fasten the case halves together.

With these steps complete, the PyBadge LC is now secured within the assembled case, and ready to be powered on or connected to a computer.