A Box with a Switch

in Product Design held by Ilina
Contest Closed
We have created an electronic unit that transmits a wireless signal when turned on. We wish to enclose this electronic unit in a plastic box that incorporates an “activation mechanism” to turn on the electronic unit. The mechanism should be designed so that the electronic unit is quick and easy to deliberately turn on in a moment of panic. However, the design should also prevent against accidental turn on. Finally, when the mechanism is turned on, it should remain turned on until explicitly turned off.

The electronic unit has the following dimensions: 28mm x 14mm x 6mm [length, width, height]. The enclosure for the electronic unit and activation mechanism must be as small as possible. We do NOT want a bulky box or bulky activation mechanism. It must be as small and sleek as possible.

This electronic unit will have two wires that, when connected, turn the unit on. Thus, these leads should be connected when the mechanism is turned on, and otherwise remain unconnected when the mechanism is turned off. If you choose to use an electronic switch to handle this, please see the additional information paragraph.

We want to 3D print this design using a ProJet. Please provide detailed images of your design, as well as the necessary CAD and LST files.

Additional Information on powering the unit using electronic switch:
If you wish to use an electronic switch to power/unpower the electronics in the mechanism, you may find the following source useful: www.omron.com/ecb/products/sw/. This manufacturer makes very small switches, with their smallest switch measuring only 3.5mm (ultra subminiature SMD switch: www.omron.com/ecb/products/search/.

For your reference, these switches can be bought in two modes:
Normally Open (NO), where the electronic unit is powered when the switch is being pushed down, and unpowered when the switch is not being pushed down.
Normally Close (NC), where the electronic unit is powered when the switch is not being pushed, and unpowered when the switch is being pushed.

You may find these modes of operation useful when creating the design. CAD files of these switches are available on Omron’s website. Of course, you may use switches from other manufacturers if they better fit your design needs.
We will evaluate based on:
- size (the smaller the box, the better)
- activation mechanism (needs to be hard to accidentally turn electronics on, but easy to turn them on deliberately)
Don't Wants:
We do not want the box to be any bigger or bulkier than necessary. The smaller the box and activating mechanism, the better!
  1. CAD
Additional Information

One more piece of information I forgot to include is that the top of the box must have a hook or ring of some kind attached to it. It is going to go on a necklace, and we need to be able to string it onto a necklace (like a pendant).


We would like to have a design as soon as possible, ideally within the next 1-2 weeks.


#7 Switch Box with Slide Button by tsalpha
Electrical switch box with slide activation button. I found a .75mm high, On-Off toggle switch, smallest one I've ever seen. Back cover can be sonicly welded, glued, fastened with screws or slide open like the battery compartment on a TV remote.
Jun 10, 2013 16:32
#6 Box whit a switch by Tsetso
I use OMRON - A9PS16-0011 switch in my design. I add a STL files for plastic parts. If you have any requirements write me to update design.
Jun 2, 2013 19:15
#5 box with a B3SNSMD type by madcadskills
I made this design because these were all the things I wish I had put in my other. They both have advantages but this one uses a programmable, more reliable button, is bigger but would be less embarrassing to wear and is held together by screws rather than pressure alone.
May 29, 2013 5:44
#4 box with rotary switch by madcadskills
the switch spins for activation and spins back for deactivation. No suggested buttons used
May 25, 2013 5:32
#3 box_with_a_switch_01 by DaBu
The outside dimensions are: 41.4mm x 15.6mm x 9mm - like a small USB stick. I used a micro slide switch from EAO (Farnell link: http://uk.farnell.com/eao/09-03201-02/switch-spst-co-0-5a-12v-pcb-blk/dp/1608080). This is a preliminary design - if you like the ideea then we can work the details. The switch is fixed in place by bending the terminals behind the plastic walls and by the two covers. The covers are locked onto each other by small plastic clips and grooves - not modelled yet. Waiting for your comments.
May 15, 2013 19:40
#2 Box with switch by Manuel Rosso
The switch used was Omron B3U. The latch is assumed programmatically.
May 13, 2013 4:16
#1 Slide Switch by Frederico
Case with custom Slide switch style mecanism, using B3F-1000 Tactile Switch (http://www.omron.com/ecb/products/sw/21/b3f.html)
No custom mechanism, using a miniature slide switch (http://www.cwind.com/pdf/Micro-Miniature-Slide-Switches-S2120_IV_06.pdf)
Dimensions: 44 (length) x16,2 (width) x 9mm (height)
Tact Switch/Slide Switch to be glued to the box,
Cover to be fixed with 3mm screw.
Can be attached to a key ring or necklace.
May 13, 2013 1:28




Sat, 11 May 2013 23:02:42 +0000
Hi Federico,

The maximum height of the electronic unit is 6 mm. So all the electronics fits within the 6 mm spec.

The switch should be continuous. If the electronics are turned on, they should stay on until they are explicitly turned off. So a toggle is the right way to think about it.
Sat, 11 May 2013 21:00:08 +0000
Is the switch operation to be momentary, or continuous (toggle)?



Sat, 11 May 2013 17:28:45 +0000
Is there any component in the eletronic unit higher than 6mm?



Fri, 10 May 2013 23:48:43 +0000
There are no inputs/outputs for the electronic unit. There are two wires coming from it that, when connected turn the electronics on, and when disconnected turn them off. So these two wires must be incorporated into the mechanism you design.

I forgot to add one detail to the spec: There should be a ring of some kind attached to the top of the box. We need this so that we can string the box onto a necklace (like a pendant).
Fri, 10 May 2013 19:17:04 +0000
Also what are the input/ out put parameters for the electronic unit, ie..signal Vcc,



Fri, 10 May 2013 18:43:21 +0000
Great question! It is to be worn as a pendant, or possibly a bracelet.
Fri, 10 May 2013 18:35:14 +0000
Is this device to be worn as a pendant or placed on a keyring? Or is it to be mounted or placed on a wall or other larger existing surface to allow easy accessibility?

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