Nice yeah I mean for prototypes it is going to be good enough initially I just wouldn’t expect long term durability out of them. I printed risers out of PLA that are going to go under a lot more impacts and stress typically and they eventually crumbled but held up for a decent amount of time considering the material properties (over a month of regular riding which was more than I expected really, think they were 25% infill and about .5" thick).
About Carbon infused PLA I haven’t used that but have heard it works well, there’s also the annealing process that is supposed to help a lot with overall part strength:
For the most part ideally the controller isn’t going through too much but occasionally I end up tossing mine or smashing it into the ground. After a year of love, and a few bails, it has started to show some age (granted my printer was in bad shape when I made it in the first place so layer adhesion wasn’t great to start). My guess is if your printer nozzle is clean and everything is extruding and sticking well then they’ll be tough enough especially with the carbon infused filament (I’ve also heard carbon infused and metal infused filaments can cause the hot end nozzle to wear down more quickly so watch out for that or use a hardened steel nozzle).
ABS just tends to be a bit more “mushy” and impact resistant so it’s less likely to crack and more likely to bend a little bit in most cases, Nylon is more extreme where it will flex a lot and won’t really ever crack, down side is it’s really hard to print with if you’re making anything large. I printed my x-carriage out of nylon and it’s no bigger than this controller and it came out well but warping and stopping water absorption is a battle with Nylon.
Really if you plan to make a lot of these I’d look at using your PLA to make a mold out of silicone then pour the parts. The initial investment in silicone is somewhat high (and there is a little learning curve) but once you have a mold you can use it for 50 parts or more and each part takes about 10-15 minutes to cure (and you can easily color the plastics or choose harder/softer plastics). This gets rid of the layer adhesion problem, you just make one nice model out of PLA and sand it down and use it as the original to make a mold then can make them pretty easily at will (just need an area you can mix up the chemicals and clean up easily). I’m in the process of doing this with my own enclosure parts but am working on 3D printing parts of the mold box too since silicone is so darn expensive and the battery boxes are pretty big and lots of empty space.
If you want to try it out this is a sample kit of the silicone and plastic it is probably enough silicone to make the molds for all the parts for your controller if you get everything right the first time around:
If not maybe one to try and one to get it right if you’re like me
The time and effort with a mold is up front and you get a lot more parts a lot quicker in the long run.