RP2040 enclosure design.
BOOTSEL still reachable.

• BOOTSEL access — the RP2040-specific one

  The RP2040 enters USB mass-storage mode by holding BOOTSEL while power cycles. Seal that button inside a printed box and you've just made firmware updates a disassembly job. We handle it one of three ways depending on how you'll actually use the thing: a plain access hole, a printed plunger over the button, or a lid that opens without tools. Which one is right is a conversation, not a default — and it's the first question we ask on an RP2040 brief.

• Castellated edges and carrier boards

  The Pico's castellated edge means it's often reflowed flat onto a carrier rather than sitting on headers. That changes the whole stack height and moves the USB connector relative to the enclosure wall. We need to know which way yours is mounted, because the two cases produce completely different interiors.

• Wireless only if you're on a W

  A base RP2040 has no radio, so antenna keep-out doesn't constrain the design — you get more freedom in wall thickness and insert placement than an ESP32 build allows. Pico W and Pico 2 W do have a radio, and those get the same 2.4 GHz keep-out treatment. Worth being explicit about which part you're on, because it genuinely changes the geometry.

• SWD and debug headers

  The three-pin debug connector is easy to forget until the enclosure is printed and you need to attach a probe. If you're still bringing the board up, we leave it accessible; if you're past that, we'll close it up and save you the opening.

RP2350 and Pico 2 boards, Pico-based carriers, and fully custom RP2040 designs are all in scope. Send the brief and we'll confirm the fit within a few hours.