Print settings: Printed using default settings on my A1 Mini using PLA.

This is a small enclosure I made for a ESPHome-enabled air quality sensor made using a generic EPS32 board from Amazon and a SEN54 air quality sensor from Sensiron. The sensor is very accurate even though I had to apply a negative temperature offset in ESPHome to compensate for the extra heat that comes from being inside the enclosure with other electric components. Everything is held in place through friction, including the lid (no screwing components required).

While this is not a tutorial, I can describe the arrangement of the electrical components as follows. The ESP32 is connected to a perfboard using female risers, and the sensiron is connected to the same board using a JST GH 6P that terminates in JST XH 6P. Power is supplied 5V by a USB to 5.5x2.1mm jack cable, connected to the perfboard using screw-in terminals. Everything is connected on the perfboard. This allows me to salvage the parts or modify the model without having to desolder components, if I decide so in the future.

The space that holds the ESP32 is oversized, but that works to our benefit to allow the cables to bend. If you do not use a perfboard like I did, or use a smaller ESP32 board, this space could be even narrower. But fixing that should be easy in Fusion (I have provided the raw files). You can simply cut a slice out of the box and then combine the pieces to make the cavity narrower to your pleasure.

I might make an improved version in the feature that routes power through the back, and places a display on the top.

Links:

Perfboard, screw in terminals, female risers: https://www.amazon.com/dp/B07NM68FXK

5.5x2.1mm jack connectors: https://www.amazon.com/dp/B08SJM2G52

USB to Jack cable: https://www.amazon.com/dp/B073SNC45F

ESP-32 (the one I used): https://www.amazon.com/dp/B08D5ZD528

SEN54 (SEN53 and SEN55 will also work): https://www.digikey.com/en/products/detail/sensirion-ag/SEN54-SDN-T/15903868

JST GH 6pin to Dupont connector (I bought this because I didn't want to buy a crimping set for JST GH): https://www.digikey.com/en/products/detail/sparkfun-electronics/CAB-23353/21679197

JST XH connector set (you'll need a crimper for these): https://www.amazon.com/Connector-Housing-Adapter-Terminal-Connectors/