Some time ago, I wanted to build my own ultrasonic wind sensor, since professional units can cost a small fortune. However, during my research I came across a great ready-made and compact solution from Calypso Instruments - a wireless (Bluetooth) ultrasonic wind sensor powered by a built-in photovoltaic cell.

Because I remove the sensor from my sailboat after every trip, I needed a protective case to keep it safe from mechanical damage and dirt during transport and storage.

So I decided to design and 3D print my own enclosure - a cylindrical case with a double-threaded screw cap. The interior is lined with 3 mm neoprene foam to absorb vibrations in case of accidental drops. I also added a small round plexiglass window in the cap to allow solar charging through the built-in photovoltaic cell without removing the device.

For smoother assembly, I used 0.2 mm clearance on the threaded surfaces, which made screwing and unscrewing much easier. The final part was printed with PLA on a Bambu Lab H2D printer in   3DEXPERIENCE Lab Munich

Really happy with how it turned out - compact, durable, and custom-fit for the sensor