Why I 3D Print My Own Enclosures – And How You Can Too

 

 

In the world of custom tech builds, especially when it comes to cybersecurity tools, presentation and protection matter just as much as performance.

 

That’s why I started 3D printing my own enclosures—and why you might want to consider it too.

 

Whether you’re building a portable penetration testing rig, a wireless signal sniffer, or an IoT project, 3D printing gives you the freedom to create enclosures that are tailored, professional, and functional. Let’s dive into why this approach works so well—and how you can start doing it yourself.

 

 

Why I Chose to 3D Print My Own Cases

 

 

1. Custom Fit for Custom Tools

Most of the tools I build at Hack n Back Tech—like the HackBox V2, Nova-RF, or Trapnet—are one-of-a-kind or built in small batches. There’s no off-the-shelf case that fits these devices properly. 3D printing allows me to design enclosures that hug the hardware perfectly, leaving room for airflow, ports, screens, antennas, and anything else I need.

 

 

                        

 

2. Function Meets Aesthetics

A good enclosure does more than protect your device—it tells a story. A sleek, functional case with a clean finish makes even the most experimental builds look professional. With 3D printing, I can experiment with different colors, textures, and design styles to match the branding and purpose of each tool.

 

 

3. Rapid Prototyping & Iteration

3D printing lets me go from idea to prototype in just hours. If a port doesn’t line up or a button needs more space, I can tweak the model in Fusion 360, reprint, and have a new version ready that same day. It’s fast, cheap, and empowers constant improvement.

 

 

4. Durability & Portability

Cybersecurity tools often travel. Whether I’m field testing or shipping devices to testers, printed cases protect internal components from dust, knocks, and everyday wear. With the right print settings and material (like PLA+, PETG, or ABS), I can build lightweight yet durable cases that go the distance.

 

 

5. Cost-Effective at Any Scale

After the initial investment in a 3D printer, each enclosure costs only pennies in material. Even after hundreds of prints, I’m still amazed at the value. Plus, the ability to print on demand means I don’t have to keep a huge inventory or rely on third-party suppliers.

 

 

How You Can Start 3D Printing Your Own Enclosures

 

If you’re new to 3D printing, getting started can feel overwhelming—but it’s easier than you think. Here’s a simple roadmap:

 

 

Step 1: Get the Right Gear

 

You don’t need a £500 printer to start. My first printer cost less than £200 and still handles most of my production today.

Recommended basics:

Printer: Creality Ender 3 or Anycubic Kobra Go

Filament: PLA+ for everyday prints, PETG for extra durability

Software: Fusion 360 (free for hobbyists) or Tinkercad (super beginner-friendly)

 

 

Step 2: Learn Basic CAD Modeling

CAD (Computer-Aided Design) is how you build the shapes that get printed. Start with simple box models, then add cutouts for screens, ports, and ventilation. There are loads of tutorials online for beginners.

If you’re building around an existing board or tool, measure everything carefully, including component heights and screw locations.

 

 

Step 3: Print & Test

Once you’ve got a model, slice it in Cura or PrusaSlicer, load it to your printer, and hit go. Expect to go through 2–3 iterations on your first try. That’s normal—and it’s part of the fun.

 

 

Step 4: Finishing Touches

Once printed, you can:

Sand edges for smoothness

Add labels or branding with paint pens or stickers

Use heat inserts or screws for modular access

 

 

Bonus: Sell or Share Your Designs

Once you’ve built a great enclosure, you can upload your STL files to sites like Printables or Thingiverse, or sell printed versions in your own online shop like I do at Hack n Back Tech.

 

 

Final Thoughts

 

3D printing your own enclosures gives you total control over how your tools look, feel, and function. It lets you bridge the gap between DIY builds and polished, professional products—without breaking the bank.

If you’ve been sitting on a project waiting for the “right case” to appear, maybe it’s time to design your own.

 

 

Want help getting started with your first case? Drop me a message or check out our builds on the blog. I’m always happy to share what I’ve learned.