Green2Heat Sensor Wall Enclosure CAD

Project Description – Development of Wall Enclosure for Green2Heat Room Sensor

The objective of this project is the development of a two-part wall enclosure in CAD for the Green2Heat room sensor (RS-HTGS-LoRa). The enclosure is designed for installation on a standard flush-mounted wall box (in-wall switch box) and must accommodate additional electronic modules.

The enclosure consists of a base unit (functional mounting part) and a front cover (design and user interface part).

1. Base Unit (Mounting and Functional Part)

The base unit serves as the central structural component and is mounted directly onto a standard flush-mounted wall box using the predefined screw holes.

A circular cut-out (approx. Ø60 mm) must be integrated into the base to allow routing of the 230V section of the room sensor into the wall box.

Key functions of the base unit:

Mechanical mounting and fixation of the Green2Heat room sensor (click/snap-in mechanism)
Routing of 230V components into the flush-mounted box
Integration and fixation of additional modules:
JST expansion board (4P)
Sensor modules (I2C / digital)
IO expander (SX1509 module)
Integration of a push button, which will be actuated by the front cover rocker
Internal cable management and strain relief
Optional: ventilation openings for temperature and humidity sensing

The base unit must be designed to allow assembly without adhesives (use of screw mounts, clips, or snap-fit features).

2. Front Cover (Design and User Interface)

The front cover is mounted onto the base unit and serves as both protective housing and visible user interface.

Key functions of the front cover:

Covers all internal components
Includes a display window for a 0.96" OLED display
Integrates a mechanical rocker, which actuates a push button located in the base unit
Provides a visually appealing, modern design suitable for residential environments
Easy mounting (snap-fit or concealed screws)
3. Mechanical Requirements
Overall dimensions:
Height: approx. 135 mm
Width: approx. 88 mm
Depth: approx. 12–20 mm (depending on component layout)
Compatibility:
Standard flush-mounted wall boxes (DIN standard)
Installation:
Flush wall mounting with clean visual integration
4. Design and Manufacturing Requirements
The enclosure must be suitable for 3D printing:
Primarily FDM (PLA, PETG, ABS)
Optionally adaptable for SLA
Wall thickness:
approx. 1.5 – 2.5 mm
Snap-fits and clips should be printable without support (if possible)
Avoid overhangs >45°
Modular design for future variants

Design requirements:

Modern, minimalistic appearance
Suitable for smart home environments
Preferably matte surface finish
5. Interfaces & Integration

The enclosure must support integration of the following components:

Green2Heat room sensor (main unit)
JST expansion board (Robotis)
Presence sensor (e.g. DFRobot SEN0610 or equivalent)
Temperature sensor (Mouser 482-90614ESFBCC000TU)
IO expander (SX1509)
OLED display (0.96")

All components will be provided.

6. Project Objective

The goal is to develop a functional and design-oriented enclosure that:

is easy to assemble
remains modular and extendable
can be used for prototyping (3D printing)
is suitable for later industrial production