Generate a perfectly fitted, 3D-printable case for your Waveshare Waveshare UPS HAT (C) for Raspberry Pi Zero. Verified 65x30mm base dimensions with Above-board covers the Pi Zero that stacks on top (~15mm from UPS HAT PCB to Pi Zero top surface).
UPS HAT integrates charger IC + buck-boost converter handling up to 2A at 5V — switching regulator dissipation approaches 1-1.5W under full load. Battery thermal management also matters — Li-ion cells prefer <45°C for longevity.
PETG handles the 40-50°C internal temperatures during charge/discharge cycles. ABS offers solvent-weld assembly for battery compartment covers. PC provides the flame rating desirable when enclosing lithium chemistry — though UL-rated enclosures require proper certification, not just material choice.
Lithium battery compartment MUST provide pressure venting — a sealed battery pouch under thermal runaway can rupture the enclosure.
USB-C input must remain user-accessible — charging is the primary user-facing interaction.
Provide visual access to battery capacity LEDs (4x green) — they are the only indicator of remaining runtime.
Pi Zero mount standoffs MUST NOT compress the battery pouch — allow 2-3mm slack in the compartment geometry.
Low-battery auto-shutoff wire (if used) exits between the HAT and the battery — route carefully to avoid pinch points.
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Mechanical properties are estimates. Validate critical loads before use.