Generate a perfectly fitted, 3D-printable case for your SparkFun SparkFun Thing Plus ESP32-S3. Verified 58.42x22.86mm base dimensions with Above-board accommodates stacked FeatherWings (~10mm per wing) and connector height.
Feather ESP32-S3 draws 250-500mW in active WiFi mode; LiPo charge + host current together can push the onboard MCP73831 charger to dissipate ~300mW briefly. Passive convection handles this in all typical enclosure configurations.
LiPo-powered Feather boards live in portable/wearable assemblies where impact resistance matters. PETG is the accessible default. PC/Nylon for robust wearable cases. ABS allows solvent-welding when the Feather integrates into a larger housing. PLA is marginal — portable cases see summer ambient above its creep threshold.
LiPo battery connector on one short edge — provide strain relief for the JST-PH pigtail; it does not tolerate repeated plug cycles well.
Below-board LiPo pocket must be insulated from all sharp solder points — battery pouches can be punctured.
FeatherWing stacking requires above-board clearance — if no wings are used, clearance can reduce.
USB-C on one short edge, LiPo on opposite — enclosure cable entries should respect this topology.
PCB antenna keepout applies: ≥10mm metal-free clearance on the antenna short edge (opposite USB-C).
STEMMA/Qwiic I2C connector on one long edge — accessible for daisy-chained sensors.
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Mechanical properties are estimates. Validate critical loads before use.