CommCrate

A proof of concept for a 3D-printable, modular emergency communications kit with interchangeable components

Overview

This project provides a modular framework for building emergency communications (EMCOMM) go-kits that can be easily customized and reconfigured without fabrication of new parts. The system uses 3D-printed structural components, module enclosures, and panel-mounted equipment to create a flexible communications platform that fits inside protective cases like Pelican cases.

Key Features:

• Modular Design - Swap equipment without redesigning the entire panel
• Case Agnostic - Move layouts between different case sizes with minimal work
• Non-Destructive - No drilling or permanent modifications to cases
• Interoperable - Uses Powerpole connectors and standard dimensions for compatibility

Project Structure

.
├── cad/              # FreeCAD source files
├── stl/              # Ready-to-print STL files
│   ├── Borders/      # Case-specific border components
│   ├── Modules/      # Equipment module enclosures
│   └── Structure/    # Rails, connectors, and mounts
└── README.md

Guide

See the Build Guide for assembly instructions.

Design Principles

This system follows several key design guidelines:

• External Power - Uses external 12V power via Powerpole connectors (not internal batteries)
• Powerpole Standard - All 12V connections use Powerpole in RRTT orientation (Red-Right, Tongue-Top)
• Standard Dimensions - Modules are 100mm wide (or 50mm for center panels), heights in 50mm increments
• 3mm Top Panels - Ensures consistent mounting across modules
• Friction-Fit Borders - Case-specific borders hold modules without permanent modifications

Example Components

This proof of concept includes designs for:

• Power distribution panel
• Network switch module
• Raspberry Pi module (ATAK server)
• Cooling fan module
• Meshtastic node integration
• Ethernet and SMA antenna pass-throughs

Specific equipment choices are for demonstration. Users should customize components for their use case.

Supported Cases

Borders are currently available for:

• Pelican 1400
• Strongway 13" frame

New borders can be designed for other cases while reusing all internal modules.

Contributing

This is a proof of concept. All CAD files are provided in FreeCAD format for modification.

License

See LICENSE file for details.