Here we are building a Premium Duplex hotspot with a custom carbon fiber case. All of our cases are our own designs and printed on Prusa 3D printers using high quality PETG materials.
We start out by inserting brass threaded inserts so we can securely fasten the internal boards without using any externally visible fasteners. The inserts are heated, then tapped in to a specifically sized support. When they cool down, they have a super strong grip.
Next, we insert the Raspberry Pi Zero and fasten it down with solid brass 11mm standoffs. These screw into the brass inserts we already installed.
The previously burned-in N5BOC Duplex board with the OLED soldered in is attached. For this custom build, we are inserting contrasting grill inserts to give it some “pop”. This unit is getting neon green.
We then attach the cover and the light pipe on the top, and add a silicon dust plug in the second accessory uUSB port. Then we test everything again to make sure the antennas are okay and we get the expected range. We’ll generally let it run this final test for 2 hours or so. Then it gets the final programming and shipped out to the customer.