Making Front Panels (for electronics and things)?

[Macavity]

A lot of you are quite into Electronics | (Observatory) "Electrics", so I wondered:
DO you have any favoured methods for *finish* stuff with a NICE Front Panel? 🙂

Recently embarked on a (another hobby!) "Synth in a Suitcase" MIDI interface:





There is very little *active* electronics for this one. Just a lot(!) of WIRES. A couple
of Arduino Megas and 48 channel ADC shields. It works on a prototype scale, so I
can complete this one "at my leisure"? The keen eyed may recognise the (typical)
redundant "Maplin" Eyepiece Case. One of the benefits of Video Astro/Imaging? 😛

AT THE moment, I  make a mock up of *front panels* using random hardboard.
Veroboard functions as a very useful "drilling guide" for pilot holes! Even *I* can 
get my holes in a line using this method? I buy (find) laser-cut Acrylic as an easy
to drill material for panels, but I don't think I can cut out NEAT Fader "Slots"?!?!? 🤔

I CAN (inkjet) print Panel Designs on thin card. I then use transparent sticky back
plastic to "protect" the result. I found an 8mm circular hole punch for controls etc.
https://www.amazon.co.uk/LoongGate-Heavy-Puncher-Single-Photos/dp/B07NQFWYRJ/

I PONDER using a professional firm to *Laser Cut* my Panel design in Acrylic?
There is a standard .dxm (CAD) file for laser cutters? Has anyone tried? Costs?
Laser cutters seem to be limited to A3 size. Maybe I could order transparent
(smaller) covers to "sandwich" smaller(!) sections of my (cardboard) printings?

I saw a nifty idea recently. The guy used a professional Printed Circuit Board
manufacturer to "etch" (and print) his front panels too. As ever, such services
seem to be far more available in the USA than the UK. 🥺    

Just wondering! "Brainstorming"random ideas etc. etc. 😸

Edited September 25, 2019 by Macavity

[Davey-T]

I've used 3mm plasticard in the past for small front panels, you can get it in faux carbon fibre if so inclined, a few years back I got some engraved by a local company.

Dave

[Alien 13]

When we used to make in house test equipment the front panel was printed onto self adhesive white plastic sheets (cant remember the name but it was tough material) then stuck onto aluminium, this formed not only the identifiers for switches etc but a drilling template.

Alan

P.S. I think it was these http://www.simpsondonald.co.uk/downloads/identification/rmkA4.pdf

Edited September 25, 2019 by Alien 13

[Dr_Ju_ju]

Depending on size & complexity, I sometimes 3D print them as well as using 2\3mm plastic sheets....

[Gina]

I've used "sticky back plastic" transparent vinyl sheet to cover printed (2D not 3D) decals for my "GinaTech" instruments, battery chargers etc. with the printed paper stuck to the front panel of the unit.  These front panels used to be aluminium but lately 3D printed.  With the aluminium the adhesive plastic sheet was wrapped round the edge of the panel.  With 3D printing it is possible to 3D print the labels by arranging a pause after printing the panel then changing filament to another colour and printing the label text and any other markings.  A separate dummy print can be used to get rid of the old colour after the colour change.  Of course, this is more easily done if you have a dual extruder.

[steppenwolf]

I am into 'white on black' for astronomy projects or 'black on white' for other projects as I like my projects to look 'functional' although I have done colour panels on the rare occasions when I have seen a small niche market for one of my designs (the last one was a mapping box for race cars see below). I simply print onto A4 self adhesive labels and cover them in transparent gloss fablon.

Funnily enough, I have just started making my own Eurorack modules and will finish them white on black but with a matt transparent fablon finish.

Auto Focus Switch

Mapping Box

 

 

[Macavity]

Very elegant there, Steve! Thanks ALL for your various ideas. I detect something of a theme
re. transparency? GMTA etc. 😎 NOT doing much today... All the hole drilling has "done my
back" at bit. lol. At least this time I managed to drill ALL the various holes the correct size(s)!
All praise to a nice NEW set of (sharp for a change!) drill bits... All hail the STEP drill notably. 😸 

Edited September 25, 2019 by Macavity

[Alien 13]

My biggest problem is finding cases for my projects, the audio ones especially as I like them to be machined out of  a block of aluminium... the extruded cases are a reasonable second best for some less critical builds.

Alan

Edited September 25, 2019 by Alien 13

[Dr_Ju_ju]

Go for the ubiquitous die cast case, i.e. https://www.ebay.co.uk/itm/Waterproof-enclosure-Instrument-Aluminium-diecast-electronics-project-box/153525629026   

easily drillable \ paintable, can even be machined.....

 

[pete_l]

13 hours ago, Alien 13 said:

My biggest problem is finding cases for my projects, the audio ones especially as I like them to be machined out of  a block of aluminium... the extruded cases are a reasonable second best for some less critical builds.

Alan

Have you looked at Reichelt's offerings?

[Macavity]

27 minutes ago, Dr_Ju_ju said:

Go for the ubiquitous die cast case...

Yes, pleased to see the ubiquitous "Eddystone Box" (for smaller projects)
had not vanished... along with (the original) Maplin. 😎

Edited September 26, 2019 by Macavity

[Gina]

I've used die-cast boxes a lot in the past but now I 3D print my own to the exact size wanted.

[JAS]

I usually use sheet aluminium for this sort of thing, you can have it punched or laser cut to any size you like if you are considering having it professionally made.

I am a sheet metal fabricator/ Programmer, if you send me a DXF file of what you want I can get you a price. We only punch we do not have a laser.

Alternatively I have also used a local engraving company. They have coloured plastic that reveals another colour underneath when engraved. They have also cut the shape out and all of the cut outs too.

Jason. 

[discardedastro]

https://www.protocase.co.uk/ are a thing for "bespoke" cases for projects, including control panels. Very flexible, but not the cheapest.

For your synth-in-a-flight-case, though, I'd find your nearest laser cutter owner. Engrave labels, cut holes, single sheet of alu. You can always paint the engravings and buff back the top layer to leave a really good high contrast finish.

[upahill]

I would go laser. Getting your own machine can be a major PITA though. I think the largest mine can do is just over A3 size, they can be found on the second hand market though, we grabbed ours for £750 and then spent another £300ish upgrading it to 80watt.

If it was up and running smoothly I would offer, but alas its back at the bottom of my "projects" list for some time. I havent actually tried acrylic yet either just MDF and hardboard - but its what ill use to make my control panels for astro stuff.

This guy on youtube makes awesome panels for his flight sim rig:

 

[Dr_Ju_ju]

It reminds me of the equipment panels, manufactured by the BBC at Avenue House, all metal 2 part construction with engraved front panel.

And yes, the BBC used to have its own 'factory' making specialized broadcasting equipment, not available from the 'mass' market, Its where I started my BBC career....

[Macavity]

The thread continues. And very interesting it is too! My <appreciation> 🙂

Still a way to go before making a final decision? For Electronics Nerds:
Now have to find the BEST way to read out multiple(!) rotary encoders
via Arduino etc. Something of a regular discussion on internet forums?! 😛

Aside: 12-way etc. (Budget) Rotary switches seem to have gone out of
fashion these days? Always good to know "chassis bashing" still exists! 😸

[Dr_Ju_ju]

If you want 12 way switches, they are still available, but you need to make them up using wafers and suitable mechanism....

e.g. https://www.ebay.co.uk/itm/Rotary-6-Wafer-Switch-18-Positions-Per-Wafer-Military-Spec/133111610450 with this one the number of switch positions is adjustable by the placement of a keyed 'washer'...….   

I used to make up loads for audio desk inputs\outputs etc.

[Macavity]

23 hours ago, Dr_Ju_ju said:

If you want 12 way switches, they are still available, but you need to make them up using wafers and suitable mechanism....

Thanks for answering a "specialist" question! No more expensive than some of the "fancy" GRAYHILL
(BCD output etc.) offerings. The demise of "good old" manual technology? Sometime you might not
want to introduce "microprocessors" (noise / complexity) into Audio / RF equipment though...

Someone remarked on future "shortage of electronic components". Start collecting VINTAGE stuff? 😸 

[Davey-T]

Not particularly relevant but reminded me of radio control models my dad built using telephone exchange rotary switches from surplus stores ( which I used to get dragged around on a Saturday )

Made a great ticktey tick noise and could produce endless combinations.

Dave