Mechanically attaching PCBs to form polyhedron

Community PCB Design
1

I’m at the early design stages of a project and I’m trying to determine the feasibility of constructing an icosahedron using PCBs for the 20 faces, similar to this http://www.adafruit.com/blog/2012/01/04 … -assembly/, however, with an easier method of readily accessing and enclosing the contents rather than cable ties.

My best idea at the moment is to use epoxy to create a lower and upper half of 10 faces each - this way the angles between faces can be fixed - alongside some simple clips or nylon PCB hinges to join both sections.

I have looked into some conventional forms of mechanically attaching PCBs, such as castellations, headers and hinged-standoffs, but I haven’t managed to come across something that allows a fixed angle other than right angles. Is there something I’ve overlooked? Can anyone suggest other options?

Thanks,

Igor

2

Did you see my StackExchange response?

3

lyndon:
Did you see my StackExchange response?

Yes, thanks for your suggestion. I’m still canvassing for design solutions, and I will then need to decide upon one in particular.

4

3D printing. If you need to mass-produce, possibly consider 3D printing some parts and then making silicone molds to cast many parts from 2-part resin.