Generate a perfectly fitted, 3D-printable case for your Raspberry Pi Foundation Raspberry Pi Zero 2 W. Verified 65x30mm base dimensions with Above-board is dominated by the 40-pin GPIO header height (~8mm unpopulated, ~12mm populated); below-board covers the microSD cage + standoff.
BCM2710A1 dissipates 0.8-2.5W; at this TDP a conservative enclosure wall can conduct heat to ambient without active airflow. Adding a small airflow slit is prudent for continuous-operation cases but not load-bearing for typical use.
The Zero's low thermal dissipation brings PLA into play — its 55°C deflection temperature is adequate for board surface temperatures that rarely exceed 40°C. PETG offers better long-term UV and moisture resistance for outdoor or semi-outdoor deployments. ABS is reserved for installations where chemical solvent welding is desired.
MicroSD slot must remain accessible — typical service operation on headless Zero deployments.
GPIO header is unpopulated on base Zero variants (solder pads only); if HAT support is required, user must solder header before enclosure fit-check.
Mini-HDMI requires an adapter or purpose-built short cable — enclosure aperture should accept a standard mini-HDMI plug (~12x5.5mm) with insertion room.
On-board WiFi (Zero W / 2W): antenna is PCB-integrated on +x corner; no metal-filled filament within 8mm of that corner.
Don't waste time with generic STL files that don't fit. Generate a custom, parametric enclosure designed exactly for your Raspberry Pi Zero 2 W hardware.
Generate your enclosure now — it's freeJoin 1,000+ makers using AI-powered CAD.
Mechanical properties are estimates. Validate critical loads before use.