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Project Type: Personal Project / Functional AM Design
Tools Used: Autodesk Fusion, 3D Printed Contour Gauge, Core One INDX, Vernier Calipers.
Skills: Reverse Engineering, Physical Profiling, CAD Modelling, Design for Additive Manufacturing (DFAM), Modular Assembly, Cable Management.
Overview:
A custom, multi-piece cable management shroud designed to conceal power strips, power bricks, and cable nests within a recessed media alcove. By digitally profiling the room’s decorative wooden skirting boards, the final enclosure drops directly into place with a flush fit against complex wall boundaries without requiring adhesives or wall fixings.
Renders were completed natively in Autodesk Fusion, with minor cleanup in Adobe Photoshop.
Reverse Engineering & Physical Profiling
Reverse Engineering & Physical Profiling
Skirting Profile Capture: Off-the-shelf cable boxes could not sit flush against the back wall due to the decorative wooden skirting board of differing profiles running along both sides of the alcove.
Tooling & Dimensional Measurement: To accurately capture the complex molding curves, a custom 3D-printed contour gauge was used to duplicate the skirting profile in situ.
Digitisation: The profiled gauge geometry was measured and reconstructed in Autodesk Fusion to serve as the exact mating boundary for the outer edges of the enclosure.
CAD Modelling & Design for AM (DFAM)
CAD Modelling & Design for AM (DFAM)
Modular 6-Part Architecture: To accommodate print bed volume constraints while spanning the full width of the alcove floor, the main body was split into six interlocking sections.
Internal Mechanical Fastening: Rather than relying on external glues or visible clips, the underside was engineered with angled internal screw bosses and joining brackets. Counter-sunk screws pull the six panels into a rigid, unified assembly.
Multi-Directional Cable Routing: Dedicated pass-through clearance notches were integrated into the top plate:
For thermal management, angled front ventilation slats facilitate passive convection cooling for enclosed power adapters while keeping internal wiring completely hidden from direct line of sight.
Conclusion
Conclusion
The final assembly provides a clean, professional aesthetic for the media nook. It successfully hides the power extension strip and cable nest behind a rigid, heat-ventilated façade. The profiled edges align with the skirting board, allowing the structure to remain self-supporting and easily removable for plug access.
Final assembly in place.
Test piece to gauge accuracy of fit.
Area before the project.
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