update some deisng parameters and add new cases

README.md

@@ -20,7 +20,7 @@ bundle install
 Then run:
 
 ```bash
-bundle exec bin/feather-case
+bin/feather-case
 ```
 
 The menu can create a case, reopen one for dimensional tuning after a test
@@ -38,6 +38,18 @@ Set `OPENSCAD=/path/to/openscad` or `BLENDER=/path/to/blender` when either
 program is installed elsewhere. The wizard checks both tools before replacing
 an existing package.
 
+The wizard can add clearance beyond either short end of the Feather PCB for
+right-angle headers, plug housings, and wire bends. Front clearance moves the
+board and its standoffs away from the USB-C wall; rear clearance extends the
+opposite end of the case.
+
+USB programming access can be omitted for a closed front wall or paired with
+an enclosed plug guide. The guide runs from the wall toward the connector and
+automatically stops short based on the configured connector overhang and end
+gap. New cases default to a 2 mm USB connector overhang, an enabled wall
+opening, and an enabled guide; with the standard 2 mm front clearance the guide
+has no inward length and behaves as the normal wall opening.
+
 Each generated directory contains a dependency-free `build.rb`. After copying
 that directory to another Ubuntu machine, run `ruby build.rb` to reproduce its
 exports and previews. The saved generator source is used by default so a
@@ -105,10 +117,20 @@ openscad -o oled-buttons.stl \
   feather_case.scad
 ```
 
-The standard stack height is `wing_count * wing_pitch`. Set
+The standard stack height is `wing_count * wing_pitch`, with a 12.25 mm default
-`stack_height_override` to the measured distance from the Feather PCB top to
+pitch. Set `stack_height_override` to the measured distance from the top surface
-the top FeatherWing PCB when using unusual headers. It takes precedence over
+of the Feather PCB to the top surface of the uppermost FeatherWing PCB when
-the computed height.
+using unusual headers. Do not include components on the Wing; profile-specific
+component heights and top gaps are added separately. The measured override
+takes precedence over the computed height.
+
+For the 128×64 OLED profile, `oled_component_height` is the height of the
+tallest board feature (the switch tops), while `oled_display_height` controls
+the display-face reference shown in the assembly preview. The defaults are
+2.4 mm and 1.5 mm above the Wing PCB, respectively. The enclosure ceiling
+remains based on the taller switches plus `oled_face_gap`, placing the display
+face about 1.7 mm below the lid's inner plane. The default 0.7 mm captive-button
+contact extension spans most of the 0.8 mm switch-to-lid gap.
 
 ## Custom wire egress
 
@@ -123,11 +145,15 @@ extra_cutouts = [
 ];
 ```
 
-Faces are `front`, `rear`, `left`, and `right`. For front/rear faces, `u` is
+Faces are `front` (the USB-C short wall), `rear` (the opposite short wall),
-the global Y coordinate; for left/right faces it is global X. The Z value is
+`left` (the plain/non-JST long wall), and `right` (the JST/battery long wall).
-the opening centre. Shapes are `circle`, `rect`, `roundrect`, and `slot`.
+For front/rear faces, `u` is the global Y coordinate; for left/right faces it
-Cutouts that enter the floor or lid-lip keepout raise an assertion instead of
+is global X. The wizard presents this as distance from the selected wall's
-silently weakening those features.
+left edge while viewing it from outside. The Z value is the opening centre.
+Shapes are `circle`, `rect`, `roundrect`, and `slot`. Cutouts that enter the
+floor or lid-lip keepout, approach another opening too closely, or overlap the
+USB opening or guide keepout raise an assertion instead of silently weakening
+those features.
 
 ## Calibration
 

bin/feather-case

@@ -1,7 +1,9 @@
 #!/usr/bin/env ruby
 # frozen_string_literal: true
 
+ENV["BUNDLE_GEMFILE"] ||= File.expand_path("../Gemfile", __dir__)
+require "bundler/setup"
+
 require_relative "../lib/feather_case_wizard"
 
 exit FeatherCaseWizard::CLI.new.run
-

cases/attitude-imu-battery/README.md

@@ -0,0 +1,25 @@
+# Attitude IMU - Battery
+
+Generated by the Feather Case Wizard.
+
+- Top profile: `generic`
+- FeatherWings: 1
+- Battery compartment: yes
+- 1/4-20 insert: yes
+- Approximate exterior: 93.9 × 57.3 × 35.8 mm
+- Formats: 3mf
+- Parts: `body`, `lid`
+- Custom cutouts: 0
+
+Run `ruby build.rb` in this directory to regenerate exports and previews.
+OpenSCAD and Blender must be installed. Set `OPENSCAD` or `BLENDER` to
+override their executable paths.
+
+To open the saved Customizer values manually:
+
+```bash
+openscad -p parameters.json -P attitude-imu-battery source/feather_case.scad
+```
+
+The 3MF files contain portable geometry only. Choose printer, filament,
+plate, and slicing settings in Bambu Studio.

cases/attitude-imu-battery/build.rb

@@ -0,0 +1,123 @@
+#!/usr/bin/env ruby
+# frozen_string_literal: true
+
+require "fileutils"
+require "json"
+require "open3"
+require "pathname"
+require "tmpdir"
+require "yaml"
+
+ROOT = Pathname(__dir__).expand_path
+
+def executable(env_name, command)
+  override = ENV[env_name]
+  return File.expand_path(override) if override && File.executable?(override)
+
+  ENV.fetch("PATH", "").split(File::PATH_SEPARATOR).each do |directory|
+    candidate = File.join(directory, command)
+    return candidate if File.file?(candidate) && File.executable?(candidate)
+  end
+  nil
+end
+
+def literal(value)
+  case value
+  when String then JSON.generate(value)
+  when TrueClass then "true"
+  when FalseClass then "false"
+  when Numeric then value.to_s
+  when Array then "[#{value.map { |item| literal(item) }.join(",")}]"
+  else raise "Cannot convert #{value.inspect} to OpenSCAD"
+  end
+end
+
+def run!(*command, env: {})
+  stdout, stderr, status = Open3.capture3(env, *command)
+  return if status.success?
+
+  warn [stdout, stderr].reject(&:empty?).join("\n")
+  raise "Command failed (#{status.exitstatus}): #{command.first}"
+end
+
+config = YAML.safe_load_file(ROOT.join("case.yml"), permitted_classes: [],
+                             permitted_symbols: [], aliases: false)
+openscad = executable("OPENSCAD", "openscad")
+blender = executable("BLENDER", "blender")
+abort "OpenSCAD not found; install it or set OPENSCAD" unless openscad
+abort "Blender not found; install it or set BLENDER" unless blender
+
+parameters = config.fetch("parameters").merge(
+  "extra_cutouts" => config.fetch("resolved").fetch("extra_cutouts")
+)
+parts = %w[body lid] + config.fetch("outputs").fetch("coupons")
+buttons = %w[button_a button_b button_c button_reset]
+if parameters["top_profile"] == "oled128x64" &&
+   buttons.any? { |name| parameters[name] }
+  parts << "buttons"
+end
+
+stage = Pathname(Dir.mktmpdir(".rebuild-", ROOT.to_s))
+begin
+  exports = stage.join("exports")
+  previews = stage.join("previews")
+  scratch = stage.join("meshes")
+  FileUtils.mkdir_p([exports, previews, scratch])
+  model = ROOT.join("source/feather_case.scad")
+  renderer = ROOT.join("source/render_stl_previews.py")
+
+  export = lambda do |output, part, overrides = {}|
+    values = parameters.merge(overrides).merge("part" => part)
+    command = [openscad, "-o", output.to_s]
+    values.each { |name, value| command.concat(["-D", "#{name}=#{literal(value)}"]) }
+    run!(*command, model.to_s)
+  end
+
+  config.fetch("outputs").fetch("formats").each do |format|
+    directory = exports.join(format)
+    FileUtils.mkdir_p(directory)
+    parts.each do |part|
+      puts "Exporting #{part}.#{format}…"
+      export.call(directory.join("#{part}.#{format}"), part)
+    end
+  end
+
+  assembly = scratch.join("assembly.stl")
+  puts "Preparing assembly preview…"
+  export.call(assembly, "assembly",
+              "exploded_view" => config.fetch("outputs").fetch("assembly_exploded_view"),
+              "show_references" => false)
+  render_env = {"DISPLAY" => nil, "WAYLAND_DISPLAY" => nil}
+  run!(blender, "--background", "-noaudio", "--python", renderer.to_s, "--",
+       assembly.to_s, previews.to_s, "assembly", env: render_env)
+  parts.each do |part|
+    puts "Rendering #{part} preview…"
+    mesh = scratch.join("#{part}.stl")
+    export.call(mesh, part) unless mesh.file?
+    run!(blender, "--background", "-noaudio", "--python", renderer.to_s, "--",
+         mesh.to_s, previews.to_s, part, "iso", env: render_env)
+  end
+
+  backup = ROOT.join(".build-old-#{Process.pid}")
+  FileUtils.mkdir_p(backup)
+  %w[exports previews].each do |name|
+    current = ROOT.join(name)
+    FileUtils.mv(current, backup.join(name)) if current.exist?
+  end
+  begin
+    FileUtils.mv(exports, ROOT.join("exports"))
+    FileUtils.mv(previews, ROOT.join("previews"))
+    FileUtils.rm_rf(backup)
+  rescue StandardError
+    FileUtils.rm_rf(ROOT.join("exports"))
+    FileUtils.rm_rf(ROOT.join("previews"))
+    %w[exports previews].each do |name|
+      saved = backup.join(name)
+      FileUtils.mv(saved, ROOT.join(name)) if saved.exist?
+    end
+    raise
+  end
+  puts "Rebuilt #{ROOT}"
+ensure
+  FileUtils.rm_rf(stage)
+end

cases/attitude-imu-battery/case.yml

@@ -0,0 +1,82 @@
+---
+schema_version: 1
+name: Attitude IMU - Battery
+slug: attitude-imu-battery
+generator:
+  sha256: be611e3255e7d802719ebb0628e3d11481f8de05fc96c24d452f026d7b8e3353
+  created_with: feather-case-wizard
+parameters:
+  top_profile: generic
+  wing_count: 1
+  wing_pitch: 12.25
+  stack_height_override: 0.0
+  generic_component_height: 3.0
+  generic_top_gap: 2.0
+  gps_antenna_height: 6.0
+  gps_top_gap: 5.0
+  oled_component_height: 2.4
+  oled_display_height: 1.5
+  oled_face_gap: 0.8
+  button_a: true
+  button_b: true
+  button_c: true
+  button_reset: false
+  button_projection: 1.5
+  button_cap_size:
+  - 5.0
+  - 3.2
+  button_flange_size:
+  - 6.6
+  - 3.6
+  button_flange_thickness: 0.9
+  button_travel: 0.5
+  button_contact_extension: 0.7
+  battery_enabled: true
+  battery_length: 69.0
+  battery_diameter: 18.0
+  battery_radial_clearance: 0.6
+  battery_end_clearance: 1.0
+  switch_hole_diameter: 12.0
+  switch_hole_compensation: 0.3
+  switch_cap_diameter: 8.0
+  switch_flange_diameter: 16.2
+  switch_body_length: 24.0
+  switch_body_diameter: 12.0
+  switch_wire_allowance: 3.0
+  tripod_insert_enabled: true
+  tripod_insert_length: 6.4
+  tripod_insert_hole_diameter: 8.8
+  tripod_thread_clearance_diameter: 6.8
+  tripod_boss_diameter: 14.0
+  m25_insert_length: 4.0
+  m25_insert_hole_diameter: 3.7
+  m25_screw_clearance: 2.8
+  m25_boss_diameter: 7.0
+  insert_entry_chamfer: 0.6
+  insert_melt_relief: 0.8
+  wall_thickness: 2.4
+  floor_thickness: 2.4
+  lid_thickness: 3.2
+  corner_radius: 4.0
+  board_bottom_clearance: 5.4
+  board_side_clearance: 7.0
+  board_rear_clearance: 4.0
+  usb_board_wall_gap: 1.2
+  lid_lip_depth: 2.4
+  lid_lip_thickness: 1.2
+  fit_clearance: 0.35
+  hole_compensation: 0.2
+  lid_screw_head_diameter: 5.2
+  lid_screw_head_height: 2.5
+  usb_opening_width: 12.5
+  usb_opening_height: 7.0
+  usb_opening_radius: 1.5
+  usb_vertical_offset: 0.0
+cutouts: []
+outputs:
+  formats:
+  - 3mf
+  coupons: []
+  assembly_exploded_view: 8
+resolved:
+  extra_cutouts: []

cases/attitude-imu-battery/parameters.json

@@ -0,0 +1,69 @@
+{
+  "parameterSets": {
+    "attitude-imu-battery": {
+      "top_profile": "\"generic\"",
+      "wing_count": "1",
+      "wing_pitch": "12.25",
+      "stack_height_override": "0.0",
+      "generic_component_height": "3.0",
+      "generic_top_gap": "2.0",
+      "gps_antenna_height": "6.0",
+      "gps_top_gap": "5.0",
+      "oled_component_height": "2.4",
+      "oled_display_height": "1.5",
+      "oled_face_gap": "0.8",
+      "button_a": "true",
+      "button_b": "true",
+      "button_c": "true",
+      "button_reset": "false",
+      "button_projection": "1.5",
+      "button_cap_size": "[5.0,3.2]",
+      "button_flange_size": "[6.6,3.6]",
+      "button_flange_thickness": "0.9",
+      "button_travel": "0.5",
+      "button_contact_extension": "0.7",
+      "battery_enabled": "true",
+      "battery_length": "69.0",
+      "battery_diameter": "18.0",
+      "battery_radial_clearance": "0.6",
+      "battery_end_clearance": "1.0",
+      "switch_hole_diameter": "12.0",
+      "switch_hole_compensation": "0.3",
+      "switch_cap_diameter": "8.0",
+      "switch_flange_diameter": "16.2",
+      "switch_body_length": "24.0",
+      "switch_body_diameter": "12.0",
+      "switch_wire_allowance": "3.0",
+      "tripod_insert_enabled": "true",
+      "tripod_insert_length": "6.4",
+      "tripod_insert_hole_diameter": "8.8",
+      "tripod_thread_clearance_diameter": "6.8",
+      "tripod_boss_diameter": "14.0",
+      "m25_insert_length": "4.0",
+      "m25_insert_hole_diameter": "3.7",
+      "m25_screw_clearance": "2.8",
+      "m25_boss_diameter": "7.0",
+      "insert_entry_chamfer": "0.6",
+      "insert_melt_relief": "0.8",
+      "wall_thickness": "2.4",
+      "floor_thickness": "2.4",
+      "lid_thickness": "3.2",
+      "corner_radius": "4.0",
+      "board_bottom_clearance": "5.4",
+      "board_side_clearance": "7.0",
+      "board_rear_clearance": "4.0",
+      "usb_board_wall_gap": "1.2",
+      "lid_lip_depth": "2.4",
+      "lid_lip_thickness": "1.2",
+      "fit_clearance": "0.35",
+      "hole_compensation": "0.2",
+      "lid_screw_head_diameter": "5.2",
+      "lid_screw_head_height": "2.5",
+      "usb_opening_width": "12.5",
+      "usb_opening_height": "7.0",
+      "usb_opening_radius": "1.5",
+      "usb_vertical_offset": "0.0"
+    }
+  },
+  "fileFormatVersion": "1"
+}

cases/attitude-imu-battery/source/feather_case.scad

@@ -0,0 +1,872 @@
+/*
+ * Parametric enclosure for the Adafruit ESP32 Feather V2 and FeatherWings.
+ *
+ * Coordinate system:
+ *   X: USB-C wall (0) toward the rear of the case
+ *   Y: non-battery side (0) toward the battery/JST side
+ *   Z: outside bottom (0) upward
+ *
+ * Board coordinates are derived from Adafruit's Eagle PCB files:
+ *   https://github.com/adafruit/Adafruit-ESP32-Feather-V2-PCB
+ *   https://github.com/adafruit/Adafruit-OLED-FeatherWing-PCB
+ */
+
+/* [Output] */
+part = "assembly"; // [assembly,body,lid,buttons,insert_coupon,switch_coupon,fit_coupon]
+exploded_view = 8; // [0:1:20]
+show_references = true;
+
+/* [Stack] */
+top_profile = "generic"; // [generic,gps,oled128x64]
+wing_count = 1; // [1:1:8]
+wing_pitch = 12.25; // [7:0.1:16]
+stack_height_override = 0; // [0:0.1:100]
+generic_component_height = 3; // [0:0.1:30]
+generic_top_gap = 2; // [0.5:0.1:10]
+gps_antenna_height = 6;
+gps_top_gap = 5;
+oled_component_height = 2.4;
+oled_display_height = 1.5;
+oled_face_gap = 0.8;
+
+/* [OLED controls] */
+button_a = true;
+button_b = true;
+button_c = true;
+button_reset = false;
+button_projection = 1.5; // [0.5:0.1:3]
+button_cap_size = [5, 3.2];
+button_flange_size = [6.6, 3.6];
+button_flange_thickness = 0.9;
+button_travel = 0.5;
+button_contact_extension = 0.7;
+
+/* [Battery and switch] */
+battery_enabled = false;
+battery_length = 69;
+battery_diameter = 18;
+battery_radial_clearance = 0.6;
+battery_end_clearance = 1;
+switch_hole_diameter = 12;
+switch_hole_compensation = 0.3;
+switch_cap_diameter = 8;
+switch_flange_diameter = 16.2;
+switch_body_length = 24;
+switch_body_diameter = 12;
+switch_wire_allowance = 3;
+
+/* [Tripod mount] */
+tripod_insert_enabled = false;
+tripod_insert_length = 6.4;
+tripod_insert_hole_diameter = 8.8;
+tripod_thread_clearance_diameter = 6.8;
+tripod_boss_diameter = 14;
+
+/* [M2.5 inserts] */
+m25_insert_length = 4;
+m25_insert_hole_diameter = 3.7;
+m25_screw_clearance = 2.8;
+m25_boss_diameter = 7;
+insert_entry_chamfer = 0.6;
+insert_melt_relief = 0.8;
+
+/* [Shell and fit] */
+wall_thickness = 2.4;
+floor_thickness = 2.4;
+lid_thickness = 3.2;
+corner_radius = 4;
+board_bottom_clearance = 5.4;
+board_side_clearance = 7;
+board_rear_clearance = 4;
+usb_board_wall_gap = 1.2;
+lid_lip_depth = 2.4;
+lid_lip_thickness = 1.2;
+fit_clearance = 0.35;
+hole_compensation = 0.2;
+lid_screw_head_diameter = 5.2;
+lid_screw_head_height = 2.5;
+
+/* [USB-C opening] */
+usb_opening_width = 12.5;
+usb_opening_height = 7;
+usb_opening_radius = 1.5;
+usb_vertical_offset = 0;
+
+/* [Custom wall cutouts] */
+// Entry format: [face, shape, u, z, width, height, radius]
+// face: front, rear, left, right. u is Y on front/rear and X on left/right.
+// shape: circle, rect, roundrect, slot. Circle uses width as its diameter.
+extra_cutouts = [];
+
+/* [Calibration] */
+coupon_steps = [-0.3, -0.15, 0, 0.15, 0.3];
+
+$fn = $preview ? 36 : 72;
+eps = 0.02;
+
+// Adafruit Feather mechanical reference, millimetres.
+feather_length = 50.8;
+feather_width = 22.86;
+board_thickness = 1.6;
+mount_x = [2.54, 48.26];
+mount_y = [2.54, 20.32];
+usb_center_y = 11.43;
+
+// Official 128x64 OLED FeatherWing geometry in Feather-board coordinates.
+oled_visible_min = [11.42, 3.78];
+oled_visible_size = [30, 15.3];
+oled_button_a_xy = [4.318, 15.875];
+oled_button_b_xy = [4.318, 11.43];
+oled_button_c_xy = [4.318, 6.985];
+oled_button_reset_xy = [7.366, 20.828];
+
+effective_floor = tripod_insert_enabled
+    ? max(floor_thickness, tripod_insert_length + insert_melt_relief + 1.2)
+    : floor_thickness;
+effective_board_clearance = max(
+    board_bottom_clearance,
+    m25_insert_length + insert_melt_relief + 0.6
+);
+
+board_origin_x = wall_thickness + usb_board_wall_gap;
+board_origin_y = wall_thickness + board_side_clearance;
+board_bottom_z = effective_floor + effective_board_clearance;
+board_top_z = board_bottom_z + board_thickness;
+
+computed_top_pcb_z = board_top_z + wing_count * wing_pitch;
+top_pcb_z = stack_height_override > 0
+    ? board_top_z + stack_height_override
+    : computed_top_pcb_z;
+profile_component_height =
+    top_profile == "gps" ? gps_antenna_height :
+    top_profile == "oled128x64" ? oled_component_height :
+    generic_component_height;
+profile_top_gap =
+    top_profile == "gps" ? gps_top_gap :
+    top_profile == "oled128x64" ? oled_face_gap :
+    generic_top_gap;
+
+partition_y = board_origin_y + feather_width + 1;
+battery_center_y = partition_y + wall_thickness + battery_radial_clearance
+    + battery_diameter / 2;
+battery_start_x = board_origin_x + battery_end_clearance;
+battery_end_x = battery_start_x + battery_length;
+switch_center_x = battery_end_x + max(
+    switch_body_diameter / 2 + 0.8,
+    switch_flange_diameter / 2 + 0.5
+);
+
+case_length_plain = board_origin_x + feather_length
+    + board_rear_clearance + wall_thickness;
+case_length_battery = switch_center_x + switch_flange_diameter / 2
+    + 1.2 + wall_thickness;
+case_length = battery_enabled ? max(case_length_plain, case_length_battery)
+    : case_length_plain;
+
+case_width_plain = board_origin_y + feather_width
+    + board_side_clearance + wall_thickness;
+case_width_battery = battery_center_y + battery_diameter / 2
+    + battery_radial_clearance + wall_thickness;
+case_width = battery_enabled ? max(case_width_plain, case_width_battery)
+    : case_width_plain;
+
+battery_center_z = effective_floor + battery_radial_clearance
+    + battery_diameter / 2;
+switch_center_z = max(
+    effective_floor + switch_flange_diameter / 2 + 1,
+    battery_center_z
+);
+electronics_ceiling_z = top_pcb_z + profile_component_height + profile_top_gap;
+battery_ceiling_z = battery_enabled
+    ? max(
+        battery_center_z + battery_diameter / 2 + battery_radial_clearance,
+        switch_center_z + switch_flange_diameter / 2 + 1
+    )
+    : 0;
+body_height = max(electronics_ceiling_z, battery_ceiling_z);
+
+lid_boss_r = m25_boss_diameter / 2;
+lid_boss_wall_overlap = 0.6;
+lid_boss_xy = [
+    [
+        wall_thickness + lid_boss_r - lid_boss_wall_overlap,
+        wall_thickness + lid_boss_r - lid_boss_wall_overlap
+    ],
+    [
+        case_length - wall_thickness - lid_boss_r + lid_boss_wall_overlap,
+        wall_thickness + lid_boss_r - lid_boss_wall_overlap
+    ],
+    [
+        wall_thickness + lid_boss_r - lid_boss_wall_overlap,
+        case_width - wall_thickness - lid_boss_r + lid_boss_wall_overlap
+    ],
+    [
+        case_length - wall_thickness - lid_boss_r + lid_boss_wall_overlap,
+        case_width - wall_thickness - lid_boss_r + lid_boss_wall_overlap
+    ]
+];
+
+assert(wing_count >= 1, "wing_count must be at least one");
+assert(top_profile == "generic" || top_profile == "gps"
+    || top_profile == "oled128x64", "Unsupported top_profile");
+assert(wall_thickness >= 1.2, "wall_thickness is too small for 0.6 mm FDM");
+assert(lid_lip_thickness >= 1.2, "lid lip needs at least two 0.6 mm lines");
+assert(m25_boss_diameter > m25_insert_hole_diameter + 2,
+    "M2.5 boss does not have enough radial material");
+assert(!tripod_insert_enabled
+    || tripod_boss_diameter > tripod_insert_hole_diameter + 3,
+    "Tripod insert boss does not have enough radial material");
+
+function clamp(v, lo, hi) = min(max(v, lo), hi);
+
+module rounded_rect_2d(size, radius) {
+    r = clamp(radius, 0.01, min(size[0], size[1]) / 2 - 0.01);
+    hull() {
+        for (x = [r, size[0] - r], y = [r, size[1] - r])
+            translate([x, y]) circle(r = r);
+    }
+}
+
+module centered_rounded_rect_2d(size, radius) {
+    translate([-size[0] / 2, -size[1] / 2])
+        rounded_rect_2d(size, radius);
+}
+
+module centered_rounded_prism(size, height, radius) {
+    linear_extrude(height = height)
+        centered_rounded_rect_2d(size, radius);
+}
+
+module rounded_box(size, radius) {
+    linear_extrude(height = size[2])
+        rounded_rect_2d([size[0], size[1]], radius);
+}
+
+module insert_pocket(diameter, depth, entry_z, downward = true) {
+    bore_d = diameter + hole_compensation;
+    if (downward) {
+        translate([0, 0, entry_z - depth])
+            cylinder(h = depth + eps, d = bore_d);
+        translate([0, 0, entry_z - insert_entry_chamfer])
+            cylinder(
+                h = insert_entry_chamfer + eps,
+                d1 = bore_d,
+                d2 = bore_d + 2 * insert_entry_chamfer
+            );
+    } else {
+        translate([0, 0, entry_z - eps])
+            cylinder(h = depth + eps, d = bore_d);
+        translate([0, 0, entry_z - eps])
+            cylinder(
+                h = insert_entry_chamfer + eps,
+                d1 = bore_d + 2 * insert_entry_chamfer,
+                d2 = bore_d
+            );
+    }
+}
+
+module face_rounded_cutout(face, u, z, width, height, radius) {
+    r = clamp(radius, 0.01, min(width, height) / 2);
+    depth = wall_thickness + 2 * eps;
+    if (face == "front" || face == "rear") {
+        x0 = face == "front" ? -eps : case_length - wall_thickness - eps;
+        hull()
+            for (yy = [u - width / 2 + r, u + width / 2 - r],
+                 zz = [z - height / 2 + r, z + height / 2 - r])
+                translate([x0, yy, zz])
+                    rotate([0, 90, 0]) cylinder(h = depth, r = r);
+    } else if (face == "left" || face == "right") {
+        y0 = face == "left" ? -eps : case_width - wall_thickness - eps;
+        hull()
+            for (xx = [u - width / 2 + r, u + width / 2 - r],
+                 zz = [z - height / 2 + r, z + height / 2 - r])
+                translate([xx, y0, zz])
+                    rotate([-90, 0, 0]) cylinder(h = depth, r = r);
+    }
+}
+
+module face_circle_cutout(face, u, z, diameter) {
+    depth = wall_thickness + 2 * eps;
+    if (face == "front")
+        translate([-eps, u, z])
+            rotate([0, 90, 0]) cylinder(h = depth, d = diameter);
+    else if (face == "rear")
+        translate([case_length - wall_thickness - eps, u, z])
+            rotate([0, 90, 0]) cylinder(h = depth, d = diameter);
+    else if (face == "left")
+        translate([u, -eps, z])
+            rotate([-90, 0, 0]) cylinder(h = depth, d = diameter);
+    else if (face == "right")
+        translate([u, case_width - wall_thickness - eps, z])
+            rotate([-90, 0, 0]) cylinder(h = depth, d = diameter);
+}
+
+module custom_wall_cutout(entry) {
+    face = entry[0];
+    shape = entry[1];
+    u = entry[2];
+    z = entry[3];
+    width = entry[4];
+    height = len(entry) > 5 ? entry[5] : width;
+    radius = len(entry) > 6 ? entry[6] : min(width, height) / 2;
+    assert(face == "front" || face == "rear"
+        || face == "left" || face == "right", "Invalid cutout face");
+    assert(shape == "circle" || shape == "rect"
+        || shape == "roundrect" || shape == "slot", "Invalid cutout shape");
+    assert(z - height / 2 >= effective_floor,
+        "Cutout intersects the floor");
+    assert(z + height / 2 <= body_height - lid_lip_depth,
+        "Cutout intersects the lid locating lip");
+    assert(
+        (face == "front" || face == "rear")
+            ? u - width / 2 >= 0 && u + width / 2 <= case_width
+            : u - width / 2 >= 0 && u + width / 2 <= case_length,
+        "Cutout extends beyond its wall"
+    );
+
+    if (shape == "circle")
+        face_circle_cutout(face, u, z, width);
+    else
+        face_rounded_cutout(
+            face, u, z, width, height,
+            shape == "rect" ? 0.02 :
+            shape == "slot" ? min(width, height) / 2 : radius
+        );
+}
+
+module board_standoffs() {
+    for (mx = mount_x, my = mount_y)
+        translate([
+            board_origin_x + mx,
+            board_origin_y + my,
+            effective_floor - eps
+        ])
+            cylinder(
+                h = effective_board_clearance + eps,
+                d = m25_boss_diameter
+            );
+}
+
+module lid_bosses() {
+    for (p = lid_boss_xy)
+        translate([p[0], p[1], effective_floor - eps])
+            cylinder(
+                h = body_height - effective_floor + eps,
+                d = m25_boss_diameter
+            );
+}
+
+module battery_cradle() {
+    partition_height = min(
+        body_height - lid_lip_depth - 0.5,
+        battery_center_z + battery_diameter / 2 + 1.5
+    );
+    rib_width = 2.4;
+    rib_positions = [
+        battery_start_x + 4,
+        (battery_start_x + battery_end_x) / 2,
+        battery_end_x - 4
+    ];
+
+    // Board/battery partition, with a lead-routing notch near the JST end.
+    difference() {
+        translate([wall_thickness, partition_y, effective_floor - eps])
+            cube([
+                battery_end_x - wall_thickness + battery_end_clearance,
+                wall_thickness,
+                partition_height - effective_floor + eps
+            ]);
+        translate([
+            board_origin_x + 6.5,
+            partition_y - eps,
+            effective_floor + 1.5
+        ])
+            cube([9, wall_thickness + 2 * eps, 6]);
+    }
+
+    // Three low curved ribs cradle the protected cylindrical pack.
+    for (x = rib_positions)
+        difference() {
+            translate([
+                x - rib_width / 2,
+                battery_center_y - battery_diameter / 2
+                    - battery_radial_clearance,
+                effective_floor - eps
+            ])
+                cube([
+                    rib_width,
+                    battery_diameter + 2 * battery_radial_clearance,
+                    battery_diameter / 2 + battery_radial_clearance + eps
+                ]);
+            translate([x - rib_width, battery_center_y, battery_center_z])
+                rotate([0, 90, 0])
+                    cylinder(
+                        h = rib_width * 2,
+                        d = battery_diameter + 2 * battery_radial_clearance
+                    );
+        }
+
+    // End stops remain below the cell center so the lid can remove vertically.
+    for (x = [
+        battery_start_x - battery_end_clearance - wall_thickness,
+        battery_end_x + battery_end_clearance
+    ])
+        translate([
+            x,
+            battery_center_y - battery_diameter / 2 - battery_radial_clearance,
+            effective_floor - eps
+        ])
+            cube([
+                wall_thickness,
+                battery_diameter + 2 * battery_radial_clearance,
+                battery_diameter / 2 + 1 + eps
+            ]);
+
+    // Rear cross-strip separates the side-mounted switch body from the cell.
+    translate([
+        battery_end_x + battery_end_clearance,
+        partition_y,
+        effective_floor - eps
+    ])
+        cube([
+            case_length - wall_thickness - battery_end_x - battery_end_clearance,
+            case_width - wall_thickness - partition_y,
+            min(body_height - effective_floor, switch_center_z
+                + switch_body_diameter / 2 + switch_wire_allowance
+                - effective_floor) + eps
+        ]);
+}
+
+module body_positive() {
+    union() {
+        difference() {
+            rounded_box([case_length, case_width, body_height], corner_radius);
+            translate([wall_thickness, wall_thickness, effective_floor])
+                rounded_box([
+                    case_length - 2 * wall_thickness,
+                    case_width - 2 * wall_thickness,
+                    body_height - effective_floor + eps
+                ], max(0.6, corner_radius - wall_thickness));
+        }
+        board_standoffs();
+        lid_bosses();
+        if (battery_enabled)
+            battery_cradle();
+        if (tripod_insert_enabled)
+            translate([case_length / 2, case_width / 2, 0])
+                cylinder(h = effective_floor, d = tripod_boss_diameter);
+    }
+}
+
+module body_cutouts() {
+    // Board mounting insert pockets, loaded from above before the Feather.
+    for (mx = mount_x, my = mount_y)
+        translate([board_origin_x + mx, board_origin_y + my, 0])
+            insert_pocket(
+                m25_insert_hole_diameter,
+                m25_insert_length + insert_melt_relief,
+                board_bottom_z
+            );
+
+    // Lid insert pockets, loaded from the top of the body.
+    for (p = lid_boss_xy)
+        translate([p[0], p[1], 0])
+            insert_pocket(
+                m25_insert_hole_diameter,
+                m25_insert_length + insert_melt_relief,
+                body_height
+            );
+
+    // USB-C cable opening. Connector center is from the official ESP32 V2 PCB.
+    usb_center_z = board_top_z + 1.6 + usb_vertical_offset;
+    face_rounded_cutout(
+        "front",
+        board_origin_y + usb_center_y,
+        usb_center_z,
+        usb_opening_width + hole_compensation,
+        usb_opening_height + hole_compensation,
+        usb_opening_radius
+    );
+
+    if (battery_enabled) {
+        face_circle_cutout(
+            "right",
+            switch_center_x,
+            switch_center_z,
+            switch_hole_diameter + switch_hole_compensation
+        );
+        // Clear the switch body and its prewired terminals through the rear bay.
+        translate([
+            switch_center_x,
+            case_width - wall_thickness + eps,
+            switch_center_z
+        ])
+            rotate([90, 0, 0])
+                cylinder(
+                    h = switch_body_length + switch_wire_allowance
+                        + wall_thickness + eps,
+                    d = switch_body_diameter + 2 * fit_clearance
+                );
+    }
+
+    if (tripod_insert_enabled) {
+        translate([case_length / 2, case_width / 2, 0]) {
+            translate([0, 0, -eps])
+                cylinder(
+                    h = effective_floor + 2 * eps,
+                    d = tripod_thread_clearance_diameter + hole_compensation
+                );
+            insert_pocket(
+                tripod_insert_hole_diameter,
+                tripod_insert_length + insert_melt_relief,
+                effective_floor
+            );
+        }
+    }
+
+    for (entry = extra_cutouts)
+        custom_wall_cutout(entry);
+}
+
+module body() {
+    difference() {
+        body_positive();
+        body_cutouts();
+    }
+}
+
+module lid_plate_positive() {
+    union() {
+        rounded_box([case_length, case_width, lid_thickness], corner_radius);
+        // Inset rim: exported pointing upward so the outer lid face prints flat.
+        translate([
+            wall_thickness + fit_clearance,
+            wall_thickness + fit_clearance,
+            lid_thickness
+        ])
+            linear_extrude(height = lid_lip_depth)
+                difference() {
+                    rounded_rect_2d([
+                        case_length - 2 * (wall_thickness + fit_clearance),
+                        case_width - 2 * (wall_thickness + fit_clearance)
+                    ], max(0.6, corner_radius - wall_thickness));
+                    translate([lid_lip_thickness, lid_lip_thickness])
+                        rounded_rect_2d([
+                            case_length - 2 * (
+                                wall_thickness + fit_clearance
+                                + lid_lip_thickness
+                            ),
+                            case_width - 2 * (
+                                wall_thickness + fit_clearance
+                                + lid_lip_thickness
+                            )
+                        ], max(0.5, corner_radius - wall_thickness
+                            - lid_lip_thickness));
+                }
+    }
+}
+
+module beveled_oled_window() {
+    inner_size = oled_visible_size;
+    outer_size = [oled_visible_size[0] + 3, oled_visible_size[1] + 3];
+    center = [
+        board_origin_x + oled_visible_min[0] + oled_visible_size[0] / 2,
+        board_origin_y + oled_visible_min[1] + oled_visible_size[1] / 2
+    ];
+    hull() {
+        translate([center[0], center[1], -eps])
+            linear_extrude(height = eps)
+                centered_rounded_rect_2d(outer_size, 1.5);
+        translate([center[0], center[1], lid_thickness - eps])
+            linear_extrude(height = 2 * eps)
+                centered_rounded_rect_2d(inner_size, 0.8);
+    }
+}
+
+module oled_button_lid_cutout(xy) {
+    center = [board_origin_x + xy[0], board_origin_y + xy[1]];
+    shaft_size = [
+        button_cap_size[0] + fit_clearance * 2,
+        button_cap_size[1] + fit_clearance * 2
+    ];
+    recess_size = [
+        button_flange_size[0] + fit_clearance * 2,
+        button_flange_size[1] + fit_clearance * 2
+    ];
+    recess_depth = button_flange_thickness + button_travel;
+    translate([center[0], center[1], -eps])
+        centered_rounded_prism(
+            shaft_size,
+            lid_thickness + 2 * eps,
+            shaft_size[1] / 2
+        );
+    translate([center[0], center[1], lid_thickness - recess_depth])
+        centered_rounded_prism(
+            recess_size,
+            recess_depth + lid_lip_depth + eps,
+            recess_size[1] / 2
+        );
+}
+
+module lid_cutouts() {
+    // Through holes plus shallow counterbores for flush M2.5 socket heads.
+    for (p = lid_boss_xy) {
+        translate([p[0], p[1], -eps])
+            cylinder(
+                h = lid_thickness + lid_lip_depth + 2 * eps,
+                d = m25_screw_clearance + hole_compensation
+            );
+        translate([p[0], p[1], -eps])
+            cylinder(
+                h = lid_screw_head_height + eps,
+                d = lid_screw_head_diameter + hole_compensation
+            );
+    }
+
+    if (top_profile == "oled128x64") {
+        beveled_oled_window();
+        if (button_a) oled_button_lid_cutout(oled_button_a_xy);
+        if (button_b) oled_button_lid_cutout(oled_button_b_xy);
+        if (button_c) oled_button_lid_cutout(oled_button_c_xy);
+        if (button_reset) oled_button_lid_cutout(oled_button_reset_xy);
+    }
+}
+
+module lid() {
+    difference() {
+        lid_plate_positive();
+        lid_cutouts();
+    }
+}
+
+module one_oled_button() {
+    recess_depth = button_flange_thickness + button_travel;
+    stem_height = lid_thickness - recess_depth + button_projection;
+    // Print outer cap face down. The flange and contact nub build upward.
+    centered_rounded_prism(
+        button_cap_size,
+        stem_height,
+        button_cap_size[1] / 2
+    );
+    translate([0, 0, stem_height])
+        centered_rounded_prism(
+            button_flange_size,
+            button_flange_thickness,
+            button_flange_size[1] / 2
+        );
+    translate([0, 0, stem_height + button_flange_thickness])
+        cylinder(h = button_contact_extension, d = 3);
+}
+
+module buttons() {
+    enabled = [
+        button_a,
+        button_b,
+        button_c,
+        button_reset
+    ];
+    count_enabled = len([for (v = enabled) if (v) 1]);
+    if (count_enabled == 0)
+        echo("No OLED buttons are enabled.");
+    for (i = [0 : len(enabled) - 1])
+        if (enabled[i])
+            translate([i * (button_flange_size[0] + 3), 0, 0])
+                one_oled_button();
+}
+
+module reference_board() {
+    color([0.05, 0.25, 0.55, 0.75])
+        translate([board_origin_x, board_origin_y, board_bottom_z])
+            rounded_box([feather_length, feather_width, board_thickness], 2.54);
+    color([0.12, 0.45, 0.75, 0.45])
+        for (i = [1 : wing_count])
+            translate([
+                board_origin_x,
+                board_origin_y,
+                board_top_z + i * wing_pitch - board_thickness
+            ])
+                rounded_box(
+                    [feather_length, feather_width, board_thickness], 2.54
+                );
+}
+
+module reference_top_feature() {
+    if (top_profile == "gps")
+        color([0.92, 0.78, 0.35, 0.8])
+            translate([
+                board_origin_x + 31,
+                board_origin_y + (feather_width - 15) / 2,
+                top_pcb_z
+            ])
+                cube([15, 15, gps_antenna_height]);
+    else if (top_profile == "oled128x64") {
+        color([0.12, 0.12, 0.12, 0.9])
+            translate([
+                board_origin_x + oled_visible_min[0],
+                board_origin_y + oled_visible_min[1],
+                top_pcb_z
+            ])
+                cube([
+                    oled_visible_size[0],
+                    oled_visible_size[1],
+                    oled_display_height
+                ]);
+        color([0.6, 0.6, 0.6, 0.9])
+            for (xy = [
+                oled_button_a_xy,
+                oled_button_b_xy,
+                oled_button_c_xy,
+                oled_button_reset_xy
+            ])
+                translate([
+                    board_origin_x + xy[0],
+                    board_origin_y + xy[1],
+                    top_pcb_z
+                ])
+                    cylinder(h = 1.6, d = 2.1);
+    } else
+        color([0.3, 0.65, 0.35, 0.6])
+            translate([
+                board_origin_x + 10,
+                board_origin_y + 4,
+                top_pcb_z
+            ])
+                cube([
+                    feather_length - 20,
+                    feather_width - 8,
+                    generic_component_height
+                ]);
+}
+
+module reference_battery_and_switch() {
+    if (battery_enabled) {
+        color([0.35, 0.18, 0.55, 0.75])
+            translate([battery_start_x, battery_center_y, battery_center_z])
+                rotate([0, 90, 0])
+                    cylinder(h = battery_length, d = battery_diameter);
+        color([0.8, 0.15, 0.1, 0.65])
+            translate([
+                switch_center_x,
+                case_width - wall_thickness,
+                switch_center_z
+            ])
+                rotate([90, 0, 0]) {
+                    cylinder(h = switch_body_length, d = switch_body_diameter);
+                    translate([0, 0, -1.5])
+                        cylinder(h = 1.5, d = switch_flange_diameter);
+                    translate([0, 0, -3])
+                        cylinder(h = 3, d = switch_cap_diameter);
+                }
+    }
+}
+
+module assembly() {
+    color([0.82, 0.84, 0.88, 1]) body();
+    if ($preview && show_references) {
+        reference_board();
+        reference_top_feature();
+        reference_battery_and_switch();
+    }
+    // Printable lid is mirrored into its installed orientation and exploded up.
+    color([0.92, 0.92, 0.95, 0.88])
+        translate([0, case_width, body_height + lid_thickness + exploded_view])
+            rotate([180, 0, 0])
+                lid();
+}
+
+module coupon_hole(x, y, diameter, depth) {
+    translate([x, y, -eps]) cylinder(h = depth + 2 * eps, d = diameter);
+}
+
+module insert_coupon() {
+    spacing = 15;
+    coupon_length = spacing * len(coupon_steps) + 8;
+    coupon_width = 32;
+    coupon_height = max(
+        m25_insert_length + insert_melt_relief + 1.2,
+        tripod_insert_length + insert_melt_relief + 1.2
+    );
+    difference() {
+        rounded_box([coupon_length, coupon_width, coupon_height], 3);
+        for (i = [0 : len(coupon_steps) - 1]) {
+            x = 7 + i * spacing;
+            coupon_hole(
+                x, 8,
+                m25_insert_hole_diameter + coupon_steps[i],
+                m25_insert_length + insert_melt_relief
+            );
+            coupon_hole(
+                x, 23,
+                tripod_insert_hole_diameter + coupon_steps[i],
+                tripod_insert_length + insert_melt_relief
+            );
+        }
+    }
+}
+
+module switch_coupon() {
+    spacing = 18;
+    coupon_length = spacing * len(coupon_steps) + 6;
+    coupon_width = 24;
+    coupon_height = wall_thickness;
+    difference() {
+        rounded_box([coupon_length, coupon_width, coupon_height], 3);
+        for (i = [0 : len(coupon_steps) - 1])
+            translate([6 + i * spacing, coupon_width / 2, -eps])
+                cylinder(
+                    h = coupon_height + 2 * eps,
+                    d = switch_hole_diameter + coupon_steps[i]
+                );
+    }
+}
+
+module fit_coupon() {
+    segment_length = 34;
+    base_width = 16;
+    base_height = 6;
+    cavity_size = [segment_length - 8, base_width - 8];
+    male_size = [
+        cavity_size[0] - 2 * fit_clearance,
+        cavity_size[1] - 2 * fit_clearance
+    ];
+    difference() {
+        rounded_box([segment_length, base_width, base_height], 2);
+        translate([4, 4, 2])
+            cube([segment_length - 8, base_width - 8, base_height]);
+    }
+    translate([segment_length + 5, 0, 0])
+        union() {
+            cube([segment_length, base_width, lid_thickness]);
+            translate([
+                4 + fit_clearance,
+                4 + fit_clearance,
+                lid_thickness - eps
+            ])
+                linear_extrude(height = lid_lip_depth + eps)
+                    difference() {
+                        rounded_rect_2d(male_size, 1);
+                        translate([lid_lip_thickness, lid_lip_thickness])
+                            rounded_rect_2d([
+                                male_size[0] - 2 * lid_lip_thickness,
+                                male_size[1] - 2 * lid_lip_thickness
+                            ], 0.5);
+                    }
+        }
+}
+
+if (part == "assembly")
+    assembly();
+else if (part == "body")
+    body();
+else if (part == "lid")
+    lid();
+else if (part == "buttons")
+    buttons();
+else if (part == "insert_coupon")
+    insert_coupon();
+else if (part == "switch_coupon")
+    switch_coupon();
+else if (part == "fit_coupon")
+    fit_coupon();
+else
+    assert(false, str("Unknown part: ", part));

cases/attitude-imu-battery/source/render_stl_previews.py

@@ -0,0 +1,127 @@
+"""Render six inspection views of an STL using Blender.
+
+Usage:
+    blender --background --python tools/render_stl_previews.py -- \
+        input.stl output-directory basename [comma-separated-views]
+"""
+
+import os
+import sys
+
+import bpy
+from mathutils import Vector
+
+
+def arguments():
+    args = sys.argv[sys.argv.index("--") + 1 :]
+    if len(args) not in (3, 4):
+        raise SystemExit(
+            "expected: input.stl output-directory basename [comma-separated-views]"
+        )
+    requested_views = args[3].split(",") if len(args) == 4 else None
+    return args[0], args[1], args[2], requested_views
+
+
+def look_at(camera, target):
+    direction = Vector(target) - camera.location
+    camera.rotation_euler = direction.to_track_quat("-Z", "Y").to_euler()
+
+
+def render_view(camera, center, span, name, direction, output_dir, basename):
+    distance = span * 2.2
+    camera.location = Vector(center) + Vector(direction).normalized() * distance
+    look_at(camera, center)
+    camera.data.type = "ORTHO"
+    camera.data.ortho_scale = span * 1.35
+    bpy.context.scene.render.filepath = os.path.join(
+        output_dir, f"{basename}_{name}.png"
+    )
+    bpy.ops.render.render(write_still=True)
+
+
+def main():
+    input_path, output_dir, basename, requested_views = arguments()
+    os.makedirs(output_dir, exist_ok=True)
+
+    bpy.ops.wm.read_factory_settings(use_empty=True)
+    bpy.ops.wm.stl_import(filepath=os.path.abspath(input_path))
+    model = bpy.context.selected_objects[0]
+    model.name = "Feather case"
+
+    material = bpy.data.materials.new("Case material")
+    material.diffuse_color = (0.16, 0.42, 0.72, 1.0)
+    material.metallic = 0.0
+    material.roughness = 0.45
+    model.data.materials.append(material)
+
+    corners = [model.matrix_world @ Vector(corner) for corner in model.bound_box]
+    mins = Vector([min(v[i] for v in corners) for i in range(3)])
+    maxs = Vector([max(v[i] for v in corners) for i in range(3)])
+    center = (mins + maxs) / 2
+    span = max(maxs - mins)
+
+    world = bpy.data.worlds.new("Inspection world")
+    world.use_nodes = True
+    world.node_tree.nodes["Background"].inputs["Color"].default_value = (
+        0.035,
+        0.04,
+        0.05,
+        1,
+    )
+    world.node_tree.nodes["Background"].inputs["Strength"].default_value = 0.5
+    bpy.context.scene.world = world
+
+    camera_data = bpy.data.cameras.new("Camera")
+    camera = bpy.data.objects.new("Camera", camera_data)
+    bpy.context.collection.objects.link(camera)
+    bpy.context.scene.camera = camera
+
+    key_data = bpy.data.lights.new("Key", type="AREA")
+    key_data.energy = 900
+    key_data.shape = "DISK"
+    key_data.size = span
+    key = bpy.data.objects.new("Key", key_data)
+    key.location = center + Vector((span, -span, span * 1.5))
+    bpy.context.collection.objects.link(key)
+
+    fill_data = bpy.data.lights.new("Fill", type="AREA")
+    fill_data.energy = 500
+    fill_data.size = span
+    fill = bpy.data.objects.new("Fill", fill_data)
+    fill.location = center + Vector((-span, span, span))
+    bpy.context.collection.objects.link(fill)
+
+    scene = bpy.context.scene
+    scene.render.engine = "BLENDER_WORKBENCH"
+    scene.render.resolution_x = 800
+    scene.render.resolution_y = 600
+    scene.render.resolution_percentage = 100
+    scene.render.image_settings.file_format = "PNG"
+    scene.render.film_transparent = False
+    scene.display.shading.light = "STUDIO"
+    scene.display.shading.color_type = "MATERIAL"
+    scene.display.shading.show_shadows = True
+    scene.display.shading.show_cavity = True
+    scene.display.shading.cavity_type = "BOTH"
+    scene.display.shading.curvature_ridge_factor = 1.5
+    scene.display.shading.curvature_valley_factor = 1.2
+
+    views = {
+        "iso": (1, -1, 0.8),
+        "front": (-1, 0, 0),
+        "back": (1, 0, 0),
+        "left": (0, -1, 0),
+        "right": (0, 1, 0),
+        "top": (0, 0, 1),
+    }
+    selected = requested_views or list(views)
+    unknown = sorted(set(selected) - set(views))
+    if unknown:
+        raise SystemExit(f"unknown views: {', '.join(unknown)}")
+    for name in selected:
+        direction = views[name]
+        render_view(camera, center, span, name, direction, output_dir, basename)
+
+
+if __name__ == "__main__":
+    main()

cases/attitude-imu/README.md

@@ -0,0 +1,25 @@
+# Attitude IMU
+
+Generated by the Feather Case Wizard.
+
+- Top profile: `generic`
+- FeatherWings: 1
+- Battery compartment: no
+- 1/4-20 insert: yes
+- Approximate exterior: 60.8 × 41.7 × 35.8 mm
+- Formats: 3mf
+- Parts: `body`, `lid`
+- Custom cutouts: 0
+
+Run `ruby build.rb` in this directory to regenerate exports and previews.
+OpenSCAD and Blender must be installed. Set `OPENSCAD` or `BLENDER` to
+override their executable paths.
+
+To open the saved Customizer values manually:
+
+```bash
+openscad -p parameters.json -P attitude-imu source/feather_case.scad
+```
+
+The 3MF files contain portable geometry only. Choose printer, filament,
+plate, and slicing settings in Bambu Studio.

cases/attitude-imu/build.rb

@@ -0,0 +1,123 @@
+#!/usr/bin/env ruby
+# frozen_string_literal: true
+
+require "fileutils"
+require "json"
+require "open3"
+require "pathname"
+require "tmpdir"
+require "yaml"
+
+ROOT = Pathname(__dir__).expand_path
+
+def executable(env_name, command)
+  override = ENV[env_name]
+  return File.expand_path(override) if override && File.executable?(override)
+
+  ENV.fetch("PATH", "").split(File::PATH_SEPARATOR).each do |directory|
+    candidate = File.join(directory, command)
+    return candidate if File.file?(candidate) && File.executable?(candidate)
+  end
+  nil
+end
+
+def literal(value)
+  case value
+  when String then JSON.generate(value)
+  when TrueClass then "true"
+  when FalseClass then "false"
+  when Numeric then value.to_s
+  when Array then "[#{value.map { |item| literal(item) }.join(",")}]"
+  else raise "Cannot convert #{value.inspect} to OpenSCAD"
+  end
+end
+
+def run!(*command, env: {})
+  stdout, stderr, status = Open3.capture3(env, *command)
+  return if status.success?
+
+  warn [stdout, stderr].reject(&:empty?).join("\n")
+  raise "Command failed (#{status.exitstatus}): #{command.first}"
+end
+
+config = YAML.safe_load_file(ROOT.join("case.yml"), permitted_classes: [],
+                             permitted_symbols: [], aliases: false)
+openscad = executable("OPENSCAD", "openscad")
+blender = executable("BLENDER", "blender")
+abort "OpenSCAD not found; install it or set OPENSCAD" unless openscad
+abort "Blender not found; install it or set BLENDER" unless blender
+
+parameters = config.fetch("parameters").merge(
+  "extra_cutouts" => config.fetch("resolved").fetch("extra_cutouts")
+)
+parts = %w[body lid] + config.fetch("outputs").fetch("coupons")
+buttons = %w[button_a button_b button_c button_reset]
+if parameters["top_profile"] == "oled128x64" &&
+   buttons.any? { |name| parameters[name] }
+  parts << "buttons"
+end
+
+stage = Pathname(Dir.mktmpdir(".rebuild-", ROOT.to_s))
+begin
+  exports = stage.join("exports")
+  previews = stage.join("previews")
+  scratch = stage.join("meshes")
+  FileUtils.mkdir_p([exports, previews, scratch])
+  model = ROOT.join("source/feather_case.scad")
+  renderer = ROOT.join("source/render_stl_previews.py")
+
+  export = lambda do |output, part, overrides = {}|
+    values = parameters.merge(overrides).merge("part" => part)
+    command = [openscad, "-o", output.to_s]
+    values.each { |name, value| command.concat(["-D", "#{name}=#{literal(value)}"]) }
+    run!(*command, model.to_s)
+  end
+
+  config.fetch("outputs").fetch("formats").each do |format|
+    directory = exports.join(format)
+    FileUtils.mkdir_p(directory)
+    parts.each do |part|
+      puts "Exporting #{part}.#{format}…"
+      export.call(directory.join("#{part}.#{format}"), part)
+    end
+  end
+
+  assembly = scratch.join("assembly.stl")
+  puts "Preparing assembly preview…"
+  export.call(assembly, "assembly",
+              "exploded_view" => config.fetch("outputs").fetch("assembly_exploded_view"),
+              "show_references" => false)
+  render_env = {"DISPLAY" => nil, "WAYLAND_DISPLAY" => nil}
+  run!(blender, "--background", "-noaudio", "--python", renderer.to_s, "--",
+       assembly.to_s, previews.to_s, "assembly", env: render_env)
+  parts.each do |part|
+    puts "Rendering #{part} preview…"
+    mesh = scratch.join("#{part}.stl")
+    export.call(mesh, part) unless mesh.file?
+    run!(blender, "--background", "-noaudio", "--python", renderer.to_s, "--",
+         mesh.to_s, previews.to_s, part, "iso", env: render_env)
+  end
+
+  backup = ROOT.join(".build-old-#{Process.pid}")
+  FileUtils.mkdir_p(backup)
+  %w[exports previews].each do |name|
+    current = ROOT.join(name)
+    FileUtils.mv(current, backup.join(name)) if current.exist?
+  end
+  begin
+    FileUtils.mv(exports, ROOT.join("exports"))
+    FileUtils.mv(previews, ROOT.join("previews"))
+    FileUtils.rm_rf(backup)
+  rescue StandardError
+    FileUtils.rm_rf(ROOT.join("exports"))
+    FileUtils.rm_rf(ROOT.join("previews"))
+    %w[exports previews].each do |name|
+      saved = backup.join(name)
+      FileUtils.mv(saved, ROOT.join(name)) if saved.exist?
+    end
+    raise
+  end
+  puts "Rebuilt #{ROOT}"
+ensure
+  FileUtils.rm_rf(stage)
+end

cases/attitude-imu/case.yml

@@ -0,0 +1,82 @@
+---
+schema_version: 1
+name: Attitude IMU
+slug: attitude-imu
+generator:
+  sha256: be611e3255e7d802719ebb0628e3d11481f8de05fc96c24d452f026d7b8e3353
+  created_with: feather-case-wizard
+parameters:
+  top_profile: generic
+  wing_count: 1
+  wing_pitch: 12.25
+  stack_height_override: 0.0
+  generic_component_height: 3.0
+  generic_top_gap: 2.0
+  gps_antenna_height: 6.0
+  gps_top_gap: 5.0
+  oled_component_height: 2.4
+  oled_display_height: 1.5
+  oled_face_gap: 0.8
+  button_a: true
+  button_b: true
+  button_c: true
+  button_reset: false
+  button_projection: 1.5
+  button_cap_size:
+  - 5.0
+  - 3.2
+  button_flange_size:
+  - 6.6
+  - 3.6
+  button_flange_thickness: 0.9
+  button_travel: 0.5
+  button_contact_extension: 0.7
+  battery_enabled: false
+  battery_length: 69.0
+  battery_diameter: 18.0
+  battery_radial_clearance: 0.6
+  battery_end_clearance: 1.0
+  switch_hole_diameter: 12.0
+  switch_hole_compensation: 0.3
+  switch_cap_diameter: 8.0
+  switch_flange_diameter: 16.2
+  switch_body_length: 24.0
+  switch_body_diameter: 12.0
+  switch_wire_allowance: 3.0
+  tripod_insert_enabled: true
+  tripod_insert_length: 6.4
+  tripod_insert_hole_diameter: 8.8
+  tripod_thread_clearance_diameter: 6.8
+  tripod_boss_diameter: 14.0
+  m25_insert_length: 4.0
+  m25_insert_hole_diameter: 3.7
+  m25_screw_clearance: 2.8
+  m25_boss_diameter: 7.0
+  insert_entry_chamfer: 0.6
+  insert_melt_relief: 0.8
+  wall_thickness: 2.4
+  floor_thickness: 2.4
+  lid_thickness: 3.2
+  corner_radius: 4.0
+  board_bottom_clearance: 5.4
+  board_side_clearance: 7.0
+  board_rear_clearance: 4.0
+  usb_board_wall_gap: 1.2
+  lid_lip_depth: 2.4
+  lid_lip_thickness: 1.2
+  fit_clearance: 0.35
+  hole_compensation: 0.2
+  lid_screw_head_diameter: 5.2
+  lid_screw_head_height: 2.5
+  usb_opening_width: 12.5
+  usb_opening_height: 7.0
+  usb_opening_radius: 1.5
+  usb_vertical_offset: 0.0
+cutouts: []
+outputs:
+  formats:
+  - 3mf
+  coupons: []
+  assembly_exploded_view: 8
+resolved:
+  extra_cutouts: []

cases/attitude-imu/parameters.json

@@ -0,0 +1,69 @@
+{
+  "parameterSets": {
+    "attitude-imu": {
+      "top_profile": "\"generic\"",
+      "wing_count": "1",
+      "wing_pitch": "12.25",
+      "stack_height_override": "0.0",
+      "generic_component_height": "3.0",
+      "generic_top_gap": "2.0",
+      "gps_antenna_height": "6.0",
+      "gps_top_gap": "5.0",
+      "oled_component_height": "2.4",
+      "oled_display_height": "1.5",
+      "oled_face_gap": "0.8",
+      "button_a": "true",
+      "button_b": "true",
+      "button_c": "true",
+      "button_reset": "false",
+      "button_projection": "1.5",
+      "button_cap_size": "[5.0,3.2]",
+      "button_flange_size": "[6.6,3.6]",
+      "button_flange_thickness": "0.9",
+      "button_travel": "0.5",
+      "button_contact_extension": "0.7",
+      "battery_enabled": "false",
+      "battery_length": "69.0",
+      "battery_diameter": "18.0",
+      "battery_radial_clearance": "0.6",
+      "battery_end_clearance": "1.0",
+      "switch_hole_diameter": "12.0",
+      "switch_hole_compensation": "0.3",
+      "switch_cap_diameter": "8.0",
+      "switch_flange_diameter": "16.2",
+      "switch_body_length": "24.0",
+      "switch_body_diameter": "12.0",
+      "switch_wire_allowance": "3.0",
+      "tripod_insert_enabled": "true",
+      "tripod_insert_length": "6.4",
+      "tripod_insert_hole_diameter": "8.8",
+      "tripod_thread_clearance_diameter": "6.8",
+      "tripod_boss_diameter": "14.0",
+      "m25_insert_length": "4.0",
+      "m25_insert_hole_diameter": "3.7",
+      "m25_screw_clearance": "2.8",
+      "m25_boss_diameter": "7.0",
+      "insert_entry_chamfer": "0.6",
+      "insert_melt_relief": "0.8",
+      "wall_thickness": "2.4",
+      "floor_thickness": "2.4",
+      "lid_thickness": "3.2",
+      "corner_radius": "4.0",
+      "board_bottom_clearance": "5.4",
+      "board_side_clearance": "7.0",
+      "board_rear_clearance": "4.0",
+      "usb_board_wall_gap": "1.2",
+      "lid_lip_depth": "2.4",
+      "lid_lip_thickness": "1.2",
+      "fit_clearance": "0.35",
+      "hole_compensation": "0.2",
+      "lid_screw_head_diameter": "5.2",
+      "lid_screw_head_height": "2.5",
+      "usb_opening_width": "12.5",
+      "usb_opening_height": "7.0",
+      "usb_opening_radius": "1.5",
+      "usb_vertical_offset": "0.0"
+    }
+  },
+  "fileFormatVersion": "1"
+}

cases/attitude-imu/source/feather_case.scad

@@ -0,0 +1,872 @@
+/*
+ * Parametric enclosure for the Adafruit ESP32 Feather V2 and FeatherWings.
+ *
+ * Coordinate system:
+ *   X: USB-C wall (0) toward the rear of the case
+ *   Y: non-battery side (0) toward the battery/JST side
+ *   Z: outside bottom (0) upward
+ *
+ * Board coordinates are derived from Adafruit's Eagle PCB files:
+ *   https://github.com/adafruit/Adafruit-ESP32-Feather-V2-PCB
+ *   https://github.com/adafruit/Adafruit-OLED-FeatherWing-PCB
+ */
+
+/* [Output] */
+part = "assembly"; // [assembly,body,lid,buttons,insert_coupon,switch_coupon,fit_coupon]
+exploded_view = 8; // [0:1:20]
+show_references = true;
+
+/* [Stack] */
+top_profile = "generic"; // [generic,gps,oled128x64]
+wing_count = 1; // [1:1:8]
+wing_pitch = 12.25; // [7:0.1:16]
+stack_height_override = 0; // [0:0.1:100]
+generic_component_height = 3; // [0:0.1:30]
+generic_top_gap = 2; // [0.5:0.1:10]
+gps_antenna_height = 6;
+gps_top_gap = 5;
+oled_component_height = 2.4;
+oled_display_height = 1.5;
+oled_face_gap = 0.8;
+
+/* [OLED controls] */
+button_a = true;
+button_b = true;
+button_c = true;
+button_reset = false;
+button_projection = 1.5; // [0.5:0.1:3]
+button_cap_size = [5, 3.2];
+button_flange_size = [6.6, 3.6];
+button_flange_thickness = 0.9;
+button_travel = 0.5;
+button_contact_extension = 0.7;
+
+/* [Battery and switch] */
+battery_enabled = false;
+battery_length = 69;
+battery_diameter = 18;
+battery_radial_clearance = 0.6;
+battery_end_clearance = 1;
+switch_hole_diameter = 12;
+switch_hole_compensation = 0.3;
+switch_cap_diameter = 8;
+switch_flange_diameter = 16.2;
+switch_body_length = 24;
+switch_body_diameter = 12;
+switch_wire_allowance = 3;
+
+/* [Tripod mount] */
+tripod_insert_enabled = false;
+tripod_insert_length = 6.4;
+tripod_insert_hole_diameter = 8.8;
+tripod_thread_clearance_diameter = 6.8;
+tripod_boss_diameter = 14;
+
+/* [M2.5 inserts] */
+m25_insert_length = 4;
+m25_insert_hole_diameter = 3.7;
+m25_screw_clearance = 2.8;
+m25_boss_diameter = 7;
+insert_entry_chamfer = 0.6;
+insert_melt_relief = 0.8;
+
+/* [Shell and fit] */
+wall_thickness = 2.4;
+floor_thickness = 2.4;
+lid_thickness = 3.2;
+corner_radius = 4;
+board_bottom_clearance = 5.4;
+board_side_clearance = 7;
+board_rear_clearance = 4;
+usb_board_wall_gap = 1.2;
+lid_lip_depth = 2.4;
+lid_lip_thickness = 1.2;
+fit_clearance = 0.35;
+hole_compensation = 0.2;
+lid_screw_head_diameter = 5.2;
+lid_screw_head_height = 2.5;
+
+/* [USB-C opening] */
+usb_opening_width = 12.5;
+usb_opening_height = 7;
+usb_opening_radius = 1.5;
+usb_vertical_offset = 0;
+
+/* [Custom wall cutouts] */
+// Entry format: [face, shape, u, z, width, height, radius]
+// face: front, rear, left, right. u is Y on front/rear and X on left/right.
+// shape: circle, rect, roundrect, slot. Circle uses width as its diameter.
+extra_cutouts = [];
+
+/* [Calibration] */
+coupon_steps = [-0.3, -0.15, 0, 0.15, 0.3];
+
+$fn = $preview ? 36 : 72;
+eps = 0.02;
+
+// Adafruit Feather mechanical reference, millimetres.
+feather_length = 50.8;
+feather_width = 22.86;
+board_thickness = 1.6;
+mount_x = [2.54, 48.26];
+mount_y = [2.54, 20.32];
+usb_center_y = 11.43;
+
+// Official 128x64 OLED FeatherWing geometry in Feather-board coordinates.
+oled_visible_min = [11.42, 3.78];
+oled_visible_size = [30, 15.3];
+oled_button_a_xy = [4.318, 15.875];
+oled_button_b_xy = [4.318, 11.43];
+oled_button_c_xy = [4.318, 6.985];
+oled_button_reset_xy = [7.366, 20.828];
+
+effective_floor = tripod_insert_enabled
+    ? max(floor_thickness, tripod_insert_length + insert_melt_relief + 1.2)
+    : floor_thickness;
+effective_board_clearance = max(
+    board_bottom_clearance,
+    m25_insert_length + insert_melt_relief + 0.6
+);
+
+board_origin_x = wall_thickness + usb_board_wall_gap;
+board_origin_y = wall_thickness + board_side_clearance;
+board_bottom_z = effective_floor + effective_board_clearance;
+board_top_z = board_bottom_z + board_thickness;
+
+computed_top_pcb_z = board_top_z + wing_count * wing_pitch;
+top_pcb_z = stack_height_override > 0
+    ? board_top_z + stack_height_override
+    : computed_top_pcb_z;
+profile_component_height =
+    top_profile == "gps" ? gps_antenna_height :
+    top_profile == "oled128x64" ? oled_component_height :
+    generic_component_height;
+profile_top_gap =
+    top_profile == "gps" ? gps_top_gap :
+    top_profile == "oled128x64" ? oled_face_gap :
+    generic_top_gap;
+
+partition_y = board_origin_y + feather_width + 1;
+battery_center_y = partition_y + wall_thickness + battery_radial_clearance
+    + battery_diameter / 2;
+battery_start_x = board_origin_x + battery_end_clearance;
+battery_end_x = battery_start_x + battery_length;
+switch_center_x = battery_end_x + max(
+    switch_body_diameter / 2 + 0.8,
+    switch_flange_diameter / 2 + 0.5
+);
+
+case_length_plain = board_origin_x + feather_length
+    + board_rear_clearance + wall_thickness;
+case_length_battery = switch_center_x + switch_flange_diameter / 2
+    + 1.2 + wall_thickness;
+case_length = battery_enabled ? max(case_length_plain, case_length_battery)
+    : case_length_plain;
+
+case_width_plain = board_origin_y + feather_width
+    + board_side_clearance + wall_thickness;
+case_width_battery = battery_center_y + battery_diameter / 2
+    + battery_radial_clearance + wall_thickness;
+case_width = battery_enabled ? max(case_width_plain, case_width_battery)
+    : case_width_plain;
+
+battery_center_z = effective_floor + battery_radial_clearance
+    + battery_diameter / 2;
+switch_center_z = max(
+    effective_floor + switch_flange_diameter / 2 + 1,
+    battery_center_z
+);
+electronics_ceiling_z = top_pcb_z + profile_component_height + profile_top_gap;
+battery_ceiling_z = battery_enabled
+    ? max(
+        battery_center_z + battery_diameter / 2 + battery_radial_clearance,
+        switch_center_z + switch_flange_diameter / 2 + 1
+    )
+    : 0;
+body_height = max(electronics_ceiling_z, battery_ceiling_z);
+
+lid_boss_r = m25_boss_diameter / 2;
+lid_boss_wall_overlap = 0.6;
+lid_boss_xy = [
+    [
+        wall_thickness + lid_boss_r - lid_boss_wall_overlap,
+        wall_thickness + lid_boss_r - lid_boss_wall_overlap
+    ],
+    [
+        case_length - wall_thickness - lid_boss_r + lid_boss_wall_overlap,
+        wall_thickness + lid_boss_r - lid_boss_wall_overlap
+    ],
+    [
+        wall_thickness + lid_boss_r - lid_boss_wall_overlap,
+        case_width - wall_thickness - lid_boss_r + lid_boss_wall_overlap
+    ],
+    [
+        case_length - wall_thickness - lid_boss_r + lid_boss_wall_overlap,
+        case_width - wall_thickness - lid_boss_r + lid_boss_wall_overlap
+    ]
+];
+
+assert(wing_count >= 1, "wing_count must be at least one");
+assert(top_profile == "generic" || top_profile == "gps"
+    || top_profile == "oled128x64", "Unsupported top_profile");
+assert(wall_thickness >= 1.2, "wall_thickness is too small for 0.6 mm FDM");
+assert(lid_lip_thickness >= 1.2, "lid lip needs at least two 0.6 mm lines");
+assert(m25_boss_diameter > m25_insert_hole_diameter + 2,
+    "M2.5 boss does not have enough radial material");
+assert(!tripod_insert_enabled
+    || tripod_boss_diameter > tripod_insert_hole_diameter + 3,
+    "Tripod insert boss does not have enough radial material");
+
+function clamp(v, lo, hi) = min(max(v, lo), hi);
+
+module rounded_rect_2d(size, radius) {
+    r = clamp(radius, 0.01, min(size[0], size[1]) / 2 - 0.01);
+    hull() {
+        for (x = [r, size[0] - r], y = [r, size[1] - r])
+            translate([x, y]) circle(r = r);
+    }
+}
+
+module centered_rounded_rect_2d(size, radius) {
+    translate([-size[0] / 2, -size[1] / 2])
+        rounded_rect_2d(size, radius);
+}
+
+module centered_rounded_prism(size, height, radius) {
+    linear_extrude(height = height)
+        centered_rounded_rect_2d(size, radius);
+}
+
+module rounded_box(size, radius) {
+    linear_extrude(height = size[2])
+        rounded_rect_2d([size[0], size[1]], radius);
+}
+
+module insert_pocket(diameter, depth, entry_z, downward = true) {
+    bore_d = diameter + hole_compensation;
+    if (downward) {
+        translate([0, 0, entry_z - depth])
+            cylinder(h = depth + eps, d = bore_d);
+        translate([0, 0, entry_z - insert_entry_chamfer])
+            cylinder(
+                h = insert_entry_chamfer + eps,
+                d1 = bore_d,
+                d2 = bore_d + 2 * insert_entry_chamfer
+            );
+    } else {
+        translate([0, 0, entry_z - eps])
+            cylinder(h = depth + eps, d = bore_d);
+        translate([0, 0, entry_z - eps])
+            cylinder(
+                h = insert_entry_chamfer + eps,
+                d1 = bore_d + 2 * insert_entry_chamfer,
+                d2 = bore_d
+            );
+    }
+}
+
+module face_rounded_cutout(face, u, z, width, height, radius) {
+    r = clamp(radius, 0.01, min(width, height) / 2);
+    depth = wall_thickness + 2 * eps;
+    if (face == "front" || face == "rear") {
+        x0 = face == "front" ? -eps : case_length - wall_thickness - eps;
+        hull()
+            for (yy = [u - width / 2 + r, u + width / 2 - r],
+                 zz = [z - height / 2 + r, z + height / 2 - r])
+                translate([x0, yy, zz])
+                    rotate([0, 90, 0]) cylinder(h = depth, r = r);
+    } else if (face == "left" || face == "right") {
+        y0 = face == "left" ? -eps : case_width - wall_thickness - eps;
+        hull()
+            for (xx = [u - width / 2 + r, u + width / 2 - r],
+                 zz = [z - height / 2 + r, z + height / 2 - r])
+                translate([xx, y0, zz])
+                    rotate([-90, 0, 0]) cylinder(h = depth, r = r);
+    }
+}
+
+module face_circle_cutout(face, u, z, diameter) {
+    depth = wall_thickness + 2 * eps;
+    if (face == "front")
+        translate([-eps, u, z])
+            rotate([0, 90, 0]) cylinder(h = depth, d = diameter);
+    else if (face == "rear")
+        translate([case_length - wall_thickness - eps, u, z])
+            rotate([0, 90, 0]) cylinder(h = depth, d = diameter);
+    else if (face == "left")
+        translate([u, -eps, z])
+            rotate([-90, 0, 0]) cylinder(h = depth, d = diameter);
+    else if (face == "right")
+        translate([u, case_width - wall_thickness - eps, z])
+            rotate([-90, 0, 0]) cylinder(h = depth, d = diameter);
+}
+
+module custom_wall_cutout(entry) {
+    face = entry[0];
+    shape = entry[1];
+    u = entry[2];
+    z = entry[3];
+    width = entry[4];
+    height = len(entry) > 5 ? entry[5] : width;
+    radius = len(entry) > 6 ? entry[6] : min(width, height) / 2;
+    assert(face == "front" || face == "rear"
+        || face == "left" || face == "right", "Invalid cutout face");
+    assert(shape == "circle" || shape == "rect"
+        || shape == "roundrect" || shape == "slot", "Invalid cutout shape");
+    assert(z - height / 2 >= effective_floor,
+        "Cutout intersects the floor");
+    assert(z + height / 2 <= body_height - lid_lip_depth,
+        "Cutout intersects the lid locating lip");
+    assert(
+        (face == "front" || face == "rear")
+            ? u - width / 2 >= 0 && u + width / 2 <= case_width
+            : u - width / 2 >= 0 && u + width / 2 <= case_length,
+        "Cutout extends beyond its wall"
+    );
+
+    if (shape == "circle")
+        face_circle_cutout(face, u, z, width);
+    else
+        face_rounded_cutout(
+            face, u, z, width, height,
+            shape == "rect" ? 0.02 :
+            shape == "slot" ? min(width, height) / 2 : radius
+        );
+}
+
+module board_standoffs() {
+    for (mx = mount_x, my = mount_y)
+        translate([
+            board_origin_x + mx,
+            board_origin_y + my,
+            effective_floor - eps
+        ])
+            cylinder(
+                h = effective_board_clearance + eps,
+                d = m25_boss_diameter
+            );
+}
+
+module lid_bosses() {
+    for (p = lid_boss_xy)
+        translate([p[0], p[1], effective_floor - eps])
+            cylinder(
+                h = body_height - effective_floor + eps,
+                d = m25_boss_diameter
+            );
+}
+
+module battery_cradle() {
+    partition_height = min(
+        body_height - lid_lip_depth - 0.5,
+        battery_center_z + battery_diameter / 2 + 1.5
+    );
+    rib_width = 2.4;
+    rib_positions = [
+        battery_start_x + 4,
+        (battery_start_x + battery_end_x) / 2,
+        battery_end_x - 4
+    ];
+
+    // Board/battery partition, with a lead-routing notch near the JST end.
+    difference() {
+        translate([wall_thickness, partition_y, effective_floor - eps])
+            cube([
+                battery_end_x - wall_thickness + battery_end_clearance,
+                wall_thickness,
+                partition_height - effective_floor + eps
+            ]);
+        translate([
+            board_origin_x + 6.5,
+            partition_y - eps,
+            effective_floor + 1.5
+        ])
+            cube([9, wall_thickness + 2 * eps, 6]);
+    }
+
+    // Three low curved ribs cradle the protected cylindrical pack.
+    for (x = rib_positions)
+        difference() {
+            translate([
+                x - rib_width / 2,
+                battery_center_y - battery_diameter / 2
+                    - battery_radial_clearance,
+                effective_floor - eps
+            ])
+                cube([
+                    rib_width,
+                    battery_diameter + 2 * battery_radial_clearance,
+                    battery_diameter / 2 + battery_radial_clearance + eps
+                ]);
+            translate([x - rib_width, battery_center_y, battery_center_z])
+                rotate([0, 90, 0])
+                    cylinder(
+                        h = rib_width * 2,
+                        d = battery_diameter + 2 * battery_radial_clearance
+                    );
+        }
+
+    // End stops remain below the cell center so the lid can remove vertically.
+    for (x = [
+        battery_start_x - battery_end_clearance - wall_thickness,
+        battery_end_x + battery_end_clearance
+    ])
+        translate([
+            x,
+            battery_center_y - battery_diameter / 2 - battery_radial_clearance,
+            effective_floor - eps
+        ])
+            cube([
+                wall_thickness,
+                battery_diameter + 2 * battery_radial_clearance,
+                battery_diameter / 2 + 1 + eps
+            ]);
+
+    // Rear cross-strip separates the side-mounted switch body from the cell.
+    translate([
+        battery_end_x + battery_end_clearance,
+        partition_y,
+        effective_floor - eps
+    ])
+        cube([
+            case_length - wall_thickness - battery_end_x - battery_end_clearance,
+            case_width - wall_thickness - partition_y,
+            min(body_height - effective_floor, switch_center_z
+                + switch_body_diameter / 2 + switch_wire_allowance
+                - effective_floor) + eps
+        ]);
+}
+
+module body_positive() {
+    union() {
+        difference() {
+            rounded_box([case_length, case_width, body_height], corner_radius);
+            translate([wall_thickness, wall_thickness, effective_floor])
+                rounded_box([
+                    case_length - 2 * wall_thickness,
+                    case_width - 2 * wall_thickness,
+                    body_height - effective_floor + eps
+                ], max(0.6, corner_radius - wall_thickness));
+        }
+        board_standoffs();
+        lid_bosses();
+        if (battery_enabled)
+            battery_cradle();
+        if (tripod_insert_enabled)
+            translate([case_length / 2, case_width / 2, 0])
+                cylinder(h = effective_floor, d = tripod_boss_diameter);
+    }
+}
+
+module body_cutouts() {
+    // Board mounting insert pockets, loaded from above before the Feather.
+    for (mx = mount_x, my = mount_y)
+        translate([board_origin_x + mx, board_origin_y + my, 0])
+            insert_pocket(
+                m25_insert_hole_diameter,
+                m25_insert_length + insert_melt_relief,
+                board_bottom_z
+            );
+
+    // Lid insert pockets, loaded from the top of the body.
+    for (p = lid_boss_xy)
+        translate([p[0], p[1], 0])
+            insert_pocket(
+                m25_insert_hole_diameter,
+                m25_insert_length + insert_melt_relief,
+                body_height
+            );
+
+    // USB-C cable opening. Connector center is from the official ESP32 V2 PCB.
+    usb_center_z = board_top_z + 1.6 + usb_vertical_offset;
+    face_rounded_cutout(
+        "front",
+        board_origin_y + usb_center_y,
+        usb_center_z,
+        usb_opening_width + hole_compensation,
+        usb_opening_height + hole_compensation,
+        usb_opening_radius
+    );
+
+    if (battery_enabled) {
+        face_circle_cutout(
+            "right",
+            switch_center_x,
+            switch_center_z,
+            switch_hole_diameter + switch_hole_compensation
+        );
+        // Clear the switch body and its prewired terminals through the rear bay.
+        translate([
+            switch_center_x,
+            case_width - wall_thickness + eps,
+            switch_center_z
+        ])
+            rotate([90, 0, 0])
+                cylinder(
+                    h = switch_body_length + switch_wire_allowance
+                        + wall_thickness + eps,
+                    d = switch_body_diameter + 2 * fit_clearance
+                );
+    }
+
+    if (tripod_insert_enabled) {
+        translate([case_length / 2, case_width / 2, 0]) {
+            translate([0, 0, -eps])
+                cylinder(
+                    h = effective_floor + 2 * eps,
+                    d = tripod_thread_clearance_diameter + hole_compensation
+                );
+            insert_pocket(
+                tripod_insert_hole_diameter,
+                tripod_insert_length + insert_melt_relief,
+                effective_floor
+            );
+        }
+    }
+
+    for (entry = extra_cutouts)
+        custom_wall_cutout(entry);
+}
+
+module body() {
+    difference() {
+        body_positive();
+        body_cutouts();
+    }
+}
+
+module lid_plate_positive() {
+    union() {
+        rounded_box([case_length, case_width, lid_thickness], corner_radius);
+        // Inset rim: exported pointing upward so the outer lid face prints flat.
+        translate([
+            wall_thickness + fit_clearance,
+            wall_thickness + fit_clearance,
+            lid_thickness
+        ])
+            linear_extrude(height = lid_lip_depth)
+                difference() {
+                    rounded_rect_2d([
+                        case_length - 2 * (wall_thickness + fit_clearance),
+                        case_width - 2 * (wall_thickness + fit_clearance)
+                    ], max(0.6, corner_radius - wall_thickness));
+                    translate([lid_lip_thickness, lid_lip_thickness])
+                        rounded_rect_2d([
+                            case_length - 2 * (
+                                wall_thickness + fit_clearance
+                                + lid_lip_thickness
+                            ),
+                            case_width - 2 * (
+                                wall_thickness + fit_clearance
+                                + lid_lip_thickness
+                            )
+                        ], max(0.5, corner_radius - wall_thickness
+                            - lid_lip_thickness));
+                }
+    }
+}
+
+module beveled_oled_window() {
+    inner_size = oled_visible_size;
+    outer_size = [oled_visible_size[0] + 3, oled_visible_size[1] + 3];
+    center = [
+        board_origin_x + oled_visible_min[0] + oled_visible_size[0] / 2,
+        board_origin_y + oled_visible_min[1] + oled_visible_size[1] / 2
+    ];
+    hull() {
+        translate([center[0], center[1], -eps])
+            linear_extrude(height = eps)
+                centered_rounded_rect_2d(outer_size, 1.5);
+        translate([center[0], center[1], lid_thickness - eps])
+            linear_extrude(height = 2 * eps)
+                centered_rounded_rect_2d(inner_size, 0.8);
+    }
+}
+
+module oled_button_lid_cutout(xy) {
+    center = [board_origin_x + xy[0], board_origin_y + xy[1]];
+    shaft_size = [
+        button_cap_size[0] + fit_clearance * 2,
+        button_cap_size[1] + fit_clearance * 2
+    ];
+    recess_size = [
+        button_flange_size[0] + fit_clearance * 2,
+        button_flange_size[1] + fit_clearance * 2
+    ];
+    recess_depth = button_flange_thickness + button_travel;
+    translate([center[0], center[1], -eps])
+        centered_rounded_prism(
+            shaft_size,
+            lid_thickness + 2 * eps,
+            shaft_size[1] / 2
+        );
+    translate([center[0], center[1], lid_thickness - recess_depth])
+        centered_rounded_prism(
+            recess_size,
+            recess_depth + lid_lip_depth + eps,
+            recess_size[1] / 2
+        );
+}
+
+module lid_cutouts() {
+    // Through holes plus shallow counterbores for flush M2.5 socket heads.
+    for (p = lid_boss_xy) {
+        translate([p[0], p[1], -eps])
+            cylinder(
+                h = lid_thickness + lid_lip_depth + 2 * eps,
+                d = m25_screw_clearance + hole_compensation
+            );
+        translate([p[0], p[1], -eps])
+            cylinder(
+                h = lid_screw_head_height + eps,
+                d = lid_screw_head_diameter + hole_compensation
+            );
+    }
+
+    if (top_profile == "oled128x64") {
+        beveled_oled_window();
+        if (button_a) oled_button_lid_cutout(oled_button_a_xy);
+        if (button_b) oled_button_lid_cutout(oled_button_b_xy);
+        if (button_c) oled_button_lid_cutout(oled_button_c_xy);
+        if (button_reset) oled_button_lid_cutout(oled_button_reset_xy);
+    }
+}
+
+module lid() {
+    difference() {
+        lid_plate_positive();
+        lid_cutouts();
+    }
+}
+
+module one_oled_button() {
+    recess_depth = button_flange_thickness + button_travel;
+    stem_height = lid_thickness - recess_depth + button_projection;
+    // Print outer cap face down. The flange and contact nub build upward.
+    centered_rounded_prism(
+        button_cap_size,
+        stem_height,
+        button_cap_size[1] / 2
+    );
+    translate([0, 0, stem_height])
+        centered_rounded_prism(
+            button_flange_size,
+            button_flange_thickness,
+            button_flange_size[1] / 2
+        );
+    translate([0, 0, stem_height + button_flange_thickness])
+        cylinder(h = button_contact_extension, d = 3);
+}
+
+module buttons() {
+    enabled = [
+        button_a,
+        button_b,
+        button_c,
+        button_reset
+    ];
+    count_enabled = len([for (v = enabled) if (v) 1]);
+    if (count_enabled == 0)
+        echo("No OLED buttons are enabled.");
+    for (i = [0 : len(enabled) - 1])
+        if (enabled[i])
+            translate([i * (button_flange_size[0] + 3), 0, 0])
+                one_oled_button();
+}
+
+module reference_board() {
+    color([0.05, 0.25, 0.55, 0.75])
+        translate([board_origin_x, board_origin_y, board_bottom_z])
+            rounded_box([feather_length, feather_width, board_thickness], 2.54);
+    color([0.12, 0.45, 0.75, 0.45])
+        for (i = [1 : wing_count])
+            translate([
+                board_origin_x,
+                board_origin_y,
+                board_top_z + i * wing_pitch - board_thickness
+            ])
+                rounded_box(
+                    [feather_length, feather_width, board_thickness], 2.54
+                );
+}
+
+module reference_top_feature() {
+    if (top_profile == "gps")
+        color([0.92, 0.78, 0.35, 0.8])
+            translate([
+                board_origin_x + 31,
+                board_origin_y + (feather_width - 15) / 2,
+                top_pcb_z
+            ])
+                cube([15, 15, gps_antenna_height]);
+    else if (top_profile == "oled128x64") {
+        color([0.12, 0.12, 0.12, 0.9])
+            translate([
+                board_origin_x + oled_visible_min[0],
+                board_origin_y + oled_visible_min[1],
+                top_pcb_z
+            ])
+                cube([
+                    oled_visible_size[0],
+                    oled_visible_size[1],
+                    oled_display_height
+                ]);
+        color([0.6, 0.6, 0.6, 0.9])
+            for (xy = [
+                oled_button_a_xy,
+                oled_button_b_xy,
+                oled_button_c_xy,
+                oled_button_reset_xy
+            ])
+                translate([
+                    board_origin_x + xy[0],
+                    board_origin_y + xy[1],
+                    top_pcb_z
+                ])
+                    cylinder(h = 1.6, d = 2.1);
+    } else
+        color([0.3, 0.65, 0.35, 0.6])
+            translate([
+                board_origin_x + 10,
+                board_origin_y + 4,
+                top_pcb_z
+            ])
+                cube([
+                    feather_length - 20,
+                    feather_width - 8,
+                    generic_component_height
+                ]);
+}
+
+module reference_battery_and_switch() {
+    if (battery_enabled) {
+        color([0.35, 0.18, 0.55, 0.75])
+            translate([battery_start_x, battery_center_y, battery_center_z])
+                rotate([0, 90, 0])
+                    cylinder(h = battery_length, d = battery_diameter);
+        color([0.8, 0.15, 0.1, 0.65])
+            translate([
+                switch_center_x,
+                case_width - wall_thickness,
+                switch_center_z
+            ])
+                rotate([90, 0, 0]) {
+                    cylinder(h = switch_body_length, d = switch_body_diameter);
+                    translate([0, 0, -1.5])
+                        cylinder(h = 1.5, d = switch_flange_diameter);
+                    translate([0, 0, -3])
+                        cylinder(h = 3, d = switch_cap_diameter);
+                }
+    }
+}
+
+module assembly() {
+    color([0.82, 0.84, 0.88, 1]) body();
+    if ($preview && show_references) {
+        reference_board();
+        reference_top_feature();
+        reference_battery_and_switch();
+    }
+    // Printable lid is mirrored into its installed orientation and exploded up.
+    color([0.92, 0.92, 0.95, 0.88])
+        translate([0, case_width, body_height + lid_thickness + exploded_view])
+            rotate([180, 0, 0])
+                lid();
+}
+
+module coupon_hole(x, y, diameter, depth) {
+    translate([x, y, -eps]) cylinder(h = depth + 2 * eps, d = diameter);
+}
+
+module insert_coupon() {
+    spacing = 15;
+    coupon_length = spacing * len(coupon_steps) + 8;
+    coupon_width = 32;
+    coupon_height = max(
+        m25_insert_length + insert_melt_relief + 1.2,
+        tripod_insert_length + insert_melt_relief + 1.2
+    );
+    difference() {
+        rounded_box([coupon_length, coupon_width, coupon_height], 3);
+        for (i = [0 : len(coupon_steps) - 1]) {
+            x = 7 + i * spacing;
+            coupon_hole(
+                x, 8,
+                m25_insert_hole_diameter + coupon_steps[i],
+                m25_insert_length + insert_melt_relief
+            );
+            coupon_hole(
+                x, 23,
+                tripod_insert_hole_diameter + coupon_steps[i],
+                tripod_insert_length + insert_melt_relief
+            );
+        }
+    }
+}
+
+module switch_coupon() {
+    spacing = 18;
+    coupon_length = spacing * len(coupon_steps) + 6;
+    coupon_width = 24;
+    coupon_height = wall_thickness;
+    difference() {
+        rounded_box([coupon_length, coupon_width, coupon_height], 3);
+        for (i = [0 : len(coupon_steps) - 1])
+            translate([6 + i * spacing, coupon_width / 2, -eps])
+                cylinder(
+                    h = coupon_height + 2 * eps,
+                    d = switch_hole_diameter + coupon_steps[i]
+                );
+    }
+}
+
+module fit_coupon() {
+    segment_length = 34;
+    base_width = 16;
+    base_height = 6;
+    cavity_size = [segment_length - 8, base_width - 8];
+    male_size = [
+        cavity_size[0] - 2 * fit_clearance,
+        cavity_size[1] - 2 * fit_clearance
+    ];
+    difference() {
+        rounded_box([segment_length, base_width, base_height], 2);
+        translate([4, 4, 2])
+            cube([segment_length - 8, base_width - 8, base_height]);
+    }
+    translate([segment_length + 5, 0, 0])
+        union() {
+            cube([segment_length, base_width, lid_thickness]);
+            translate([
+                4 + fit_clearance,
+                4 + fit_clearance,
+                lid_thickness - eps
+            ])
+                linear_extrude(height = lid_lip_depth + eps)
+                    difference() {
+                        rounded_rect_2d(male_size, 1);
+                        translate([lid_lip_thickness, lid_lip_thickness])
+                            rounded_rect_2d([
+                                male_size[0] - 2 * lid_lip_thickness,
+                                male_size[1] - 2 * lid_lip_thickness
+                            ], 0.5);
+                    }
+        }
+}
+
+if (part == "assembly")
+    assembly();
+else if (part == "body")
+    body();
+else if (part == "lid")
+    lid();
+else if (part == "buttons")
+    buttons();
+else if (part == "insert_coupon")
+    insert_coupon();
+else if (part == "switch_coupon")
+    switch_coupon();
+else if (part == "fit_coupon")
+    fit_coupon();
+else
+    assert(false, str("Unknown part: ", part));

cases/attitude-imu/source/render_stl_previews.py

@@ -0,0 +1,127 @@
+"""Render six inspection views of an STL using Blender.
+
+Usage:
+    blender --background --python tools/render_stl_previews.py -- \
+        input.stl output-directory basename [comma-separated-views]
+"""
+
+import os
+import sys
+
+import bpy
+from mathutils import Vector
+
+
+def arguments():
+    args = sys.argv[sys.argv.index("--") + 1 :]
+    if len(args) not in (3, 4):
+        raise SystemExit(
+            "expected: input.stl output-directory basename [comma-separated-views]"
+        )
+    requested_views = args[3].split(",") if len(args) == 4 else None
+    return args[0], args[1], args[2], requested_views
+
+
+def look_at(camera, target):
+    direction = Vector(target) - camera.location
+    camera.rotation_euler = direction.to_track_quat("-Z", "Y").to_euler()
+
+
+def render_view(camera, center, span, name, direction, output_dir, basename):
+    distance = span * 2.2
+    camera.location = Vector(center) + Vector(direction).normalized() * distance
+    look_at(camera, center)
+    camera.data.type = "ORTHO"
+    camera.data.ortho_scale = span * 1.35
+    bpy.context.scene.render.filepath = os.path.join(
+        output_dir, f"{basename}_{name}.png"
+    )
+    bpy.ops.render.render(write_still=True)
+
+
+def main():
+    input_path, output_dir, basename, requested_views = arguments()
+    os.makedirs(output_dir, exist_ok=True)
+
+    bpy.ops.wm.read_factory_settings(use_empty=True)
+    bpy.ops.wm.stl_import(filepath=os.path.abspath(input_path))
+    model = bpy.context.selected_objects[0]
+    model.name = "Feather case"
+
+    material = bpy.data.materials.new("Case material")
+    material.diffuse_color = (0.16, 0.42, 0.72, 1.0)
+    material.metallic = 0.0
+    material.roughness = 0.45
+    model.data.materials.append(material)
+
+    corners = [model.matrix_world @ Vector(corner) for corner in model.bound_box]
+    mins = Vector([min(v[i] for v in corners) for i in range(3)])
+    maxs = Vector([max(v[i] for v in corners) for i in range(3)])
+    center = (mins + maxs) / 2
+    span = max(maxs - mins)
+
+    world = bpy.data.worlds.new("Inspection world")
+    world.use_nodes = True
+    world.node_tree.nodes["Background"].inputs["Color"].default_value = (
+        0.035,
+        0.04,
+        0.05,
+        1,
+    )
+    world.node_tree.nodes["Background"].inputs["Strength"].default_value = 0.5
+    bpy.context.scene.world = world
+
+    camera_data = bpy.data.cameras.new("Camera")
+    camera = bpy.data.objects.new("Camera", camera_data)
+    bpy.context.collection.objects.link(camera)
+    bpy.context.scene.camera = camera
+
+    key_data = bpy.data.lights.new("Key", type="AREA")
+    key_data.energy = 900
+    key_data.shape = "DISK"
+    key_data.size = span
+    key = bpy.data.objects.new("Key", key_data)
+    key.location = center + Vector((span, -span, span * 1.5))
+    bpy.context.collection.objects.link(key)
+
+    fill_data = bpy.data.lights.new("Fill", type="AREA")
+    fill_data.energy = 500
+    fill_data.size = span
+    fill = bpy.data.objects.new("Fill", fill_data)
+    fill.location = center + Vector((-span, span, span))
+    bpy.context.collection.objects.link(fill)
+
+    scene = bpy.context.scene
+    scene.render.engine = "BLENDER_WORKBENCH"
+    scene.render.resolution_x = 800
+    scene.render.resolution_y = 600
+    scene.render.resolution_percentage = 100
+    scene.render.image_settings.file_format = "PNG"
+    scene.render.film_transparent = False
+    scene.display.shading.light = "STUDIO"
+    scene.display.shading.color_type = "MATERIAL"
+    scene.display.shading.show_shadows = True
+    scene.display.shading.show_cavity = True
+    scene.display.shading.cavity_type = "BOTH"
+    scene.display.shading.curvature_ridge_factor = 1.5
+    scene.display.shading.curvature_valley_factor = 1.2
+
+    views = {
+        "iso": (1, -1, 0.8),
+        "front": (-1, 0, 0),
+        "back": (1, 0, 0),
+        "left": (0, -1, 0),
+        "right": (0, 1, 0),
+        "top": (0, 0, 1),
+    }
+    selected = requested_views or list(views)
+    unknown = sorted(set(selected) - set(views))
+    if unknown:
+        raise SystemExit(f"unknown views: {', '.join(unknown)}")
+    for name in selected:
+        direction = views[name]
+        render_view(camera, center, span, name, direction, output_dir, basename)
+
+
+if __name__ == "__main__":
+    main()

cases/gps/README.md

@@ -6,9 +6,9 @@ Generated by the Feather Case Wizard.
 - FeatherWings: 1
 - Battery compartment: yes
 - 1/4-20 insert: yes
-- Approximate exterior: 93.9 × 57.3 × 38.6 mm
+- Approximate exterior: 93.9 × 57.3 × 41.8 mm
 - Formats: 3mf
-- Parts: `body`, `lid`
+- Parts: `body`, `lid`, `insert_coupon`, `switch_coupon`, `fit_coupon`
 - Custom cutouts: 0
 
 Run `ruby build.rb` in this directory to regenerate exports and previews.

cases/gps/case.yml

@@ -3,18 +3,19 @@ schema_version: 1
 name: GPS
 slug: gps
 generator:
-  sha256: a265164909faa0c364792224601af36381744a129b7cd7cbd6b6293815953f63
+  sha256: be611e3255e7d802719ebb0628e3d11481f8de05fc96c24d452f026d7b8e3353
   created_with: feather-case-wizard
 parameters:
   top_profile: gps
   wing_count: 1
-  wing_pitch: 11.0
+  wing_pitch: 12.25
-  stack_height_override: 0.0
+  stack_height_override: 12.25
   generic_component_height: 3.0
   generic_top_gap: 2.0
-  gps_antenna_height: 4.0
+  gps_antenna_height: 6.0
   gps_top_gap: 5.0
   oled_component_height: 2.4
+  oled_display_height: 1.5
   oled_face_gap: 0.8
   button_a: true
   button_b: true
@@ -75,7 +76,10 @@ cutouts: []
 outputs:
   formats:
   - 3mf
-  coupons: []
+  coupons:
+  - insert_coupon
+  - switch_coupon
+  - fit_coupon
   assembly_exploded_view: 8
 resolved:
   extra_cutouts: []

cases/gps/parameters.json

@@ -3,13 +3,14 @@
     "gps": {
       "top_profile": "\"gps\"",
       "wing_count": "1",
-      "wing_pitch": "11.0",
+      "wing_pitch": "12.25",
-      "stack_height_override": "0.0",
+      "stack_height_override": "12.25",
       "generic_component_height": "3.0",
       "generic_top_gap": "2.0",
-      "gps_antenna_height": "4.0",
+      "gps_antenna_height": "6.0",
       "gps_top_gap": "5.0",
       "oled_component_height": "2.4",
+      "oled_display_height": "1.5",
       "oled_face_gap": "0.8",
       "button_a": "true",
       "button_b": "true",

cases/gps/source/feather_case.scad

@@ -19,13 +19,14 @@ show_references = true;
 /* [Stack] */
 top_profile = "generic"; // [generic,gps,oled128x64]
 wing_count = 1; // [1:1:8]
-wing_pitch = 11; // [7:0.1:16]
+wing_pitch = 12.25; // [7:0.1:16]
 stack_height_override = 0; // [0:0.1:100]
 generic_component_height = 3; // [0:0.1:30]
 generic_top_gap = 2; // [0.5:0.1:10]
-gps_antenna_height = 4;
+gps_antenna_height = 6;
 gps_top_gap = 5;
 oled_component_height = 2.4;
+oled_display_height = 1.5;
 oled_face_gap = 0.8;
 
 /* [OLED controls] */
@@ -708,7 +709,7 @@ module reference_top_feature() {
                 cube([
                     oled_visible_size[0],
                     oled_visible_size[1],
-                    oled_component_height
+                    oled_display_height
                 ]);
         color([0.6, 0.6, 0.6, 0.9])
             for (xy = [

cases/pan-tilt-head/README.md

@@ -0,0 +1,25 @@
+# Pan/Tilt Head
+
+Generated by the Feather Case Wizard.
+
+- Top profile: `oled128x64`
+- FeatherWings: 3
+- Battery compartment: no
+- 1/4-20 insert: yes
+- Approximate exterior: 95.6 × 41.7 × 59.8 mm
+- Formats: 3mf
+- Parts: `body`, `lid`, `buttons`
+- Custom cutouts: 4
+
+Run `ruby build.rb` in this directory to regenerate exports and previews.
+OpenSCAD and Blender must be installed. Set `OPENSCAD` or `BLENDER` to
+override their executable paths.
+
+To open the saved Customizer values manually:
+
+```bash
+openscad -p parameters.json -P pan-tilt-head source/feather_case.scad
+```
+
+The 3MF files contain portable geometry only. Choose printer, filament,
+plate, and slicing settings in Bambu Studio.

cases/pan-tilt-head/build.rb

@@ -0,0 +1,123 @@
+#!/usr/bin/env ruby
+# frozen_string_literal: true
+
+require "fileutils"
+require "json"
+require "open3"
+require "pathname"
+require "tmpdir"
+require "yaml"
+
+ROOT = Pathname(__dir__).expand_path
+
+def executable(env_name, command)
+  override = ENV[env_name]
+  return File.expand_path(override) if override && File.executable?(override)
+
+  ENV.fetch("PATH", "").split(File::PATH_SEPARATOR).each do |directory|
+    candidate = File.join(directory, command)
+    return candidate if File.file?(candidate) && File.executable?(candidate)
+  end
+  nil
+end
+
+def literal(value)
+  case value
+  when String then JSON.generate(value)
+  when TrueClass then "true"
+  when FalseClass then "false"
+  when Numeric then value.to_s
+  when Array then "[#{value.map { |item| literal(item) }.join(",")}]"
+  else raise "Cannot convert #{value.inspect} to OpenSCAD"
+  end
+end
+
+def run!(*command, env: {})
+  stdout, stderr, status = Open3.capture3(env, *command)
+  return if status.success?
+
+  warn [stdout, stderr].reject(&:empty?).join("\n")
+  raise "Command failed (#{status.exitstatus}): #{command.first}"
+end
+
+config = YAML.safe_load_file(ROOT.join("case.yml"), permitted_classes: [],
+                             permitted_symbols: [], aliases: false)
+openscad = executable("OPENSCAD", "openscad")
+blender = executable("BLENDER", "blender")
+abort "OpenSCAD not found; install it or set OPENSCAD" unless openscad
+abort "Blender not found; install it or set BLENDER" unless blender
+
+parameters = config.fetch("parameters").merge(
+  "extra_cutouts" => config.fetch("resolved").fetch("extra_cutouts")
+)
+parts = %w[body lid] + config.fetch("outputs").fetch("coupons")
+buttons = %w[button_a button_b button_c button_reset]
+if parameters["top_profile"] == "oled128x64" &&
+   buttons.any? { |name| parameters[name] }
+  parts << "buttons"
+end
+
+stage = Pathname(Dir.mktmpdir(".rebuild-", ROOT.to_s))
+begin
+  exports = stage.join("exports")
+  previews = stage.join("previews")
+  scratch = stage.join("meshes")
+  FileUtils.mkdir_p([exports, previews, scratch])
+  model = ROOT.join("source/feather_case.scad")
+  renderer = ROOT.join("source/render_stl_previews.py")
+
+  export = lambda do |output, part, overrides = {}|
+    values = parameters.merge(overrides).merge("part" => part)
+    command = [openscad, "-o", output.to_s]
+    values.each { |name, value| command.concat(["-D", "#{name}=#{literal(value)}"]) }
+    run!(*command, model.to_s)
+  end
+
+  config.fetch("outputs").fetch("formats").each do |format|
+    directory = exports.join(format)
+    FileUtils.mkdir_p(directory)
+    parts.each do |part|
+      puts "Exporting #{part}.#{format}…"
+      export.call(directory.join("#{part}.#{format}"), part)
+    end
+  end
+
+  assembly = scratch.join("assembly.stl")
+  puts "Preparing assembly preview…"
+  export.call(assembly, "assembly",
+              "exploded_view" => config.fetch("outputs").fetch("assembly_exploded_view"),
+              "show_references" => false)
+  render_env = {"DISPLAY" => nil, "WAYLAND_DISPLAY" => nil}
+  run!(blender, "--background", "-noaudio", "--python", renderer.to_s, "--",
+       assembly.to_s, previews.to_s, "assembly", env: render_env)
+  parts.each do |part|
+    puts "Rendering #{part} preview…"
+    mesh = scratch.join("#{part}.stl")
+    export.call(mesh, part) unless mesh.file?
+    run!(blender, "--background", "-noaudio", "--python", renderer.to_s, "--",
+         mesh.to_s, previews.to_s, part, "iso", env: render_env)
+  end
+
+  backup = ROOT.join(".build-old-#{Process.pid}")
+  FileUtils.mkdir_p(backup)
+  %w[exports previews].each do |name|
+    current = ROOT.join(name)
+    FileUtils.mv(current, backup.join(name)) if current.exist?
+  end
+  begin
+    FileUtils.mv(exports, ROOT.join("exports"))
+    FileUtils.mv(previews, ROOT.join("previews"))
+    FileUtils.rm_rf(backup)
+  rescue StandardError
+    FileUtils.rm_rf(ROOT.join("exports"))
+    FileUtils.rm_rf(ROOT.join("previews"))
+    %w[exports previews].each do |name|
+      saved = backup.join(name)
+      FileUtils.mv(saved, ROOT.join(name)) if saved.exist?
+    end
+    raise
+  end
+  puts "Rebuilt #{ROOT}"
+ensure
+  FileUtils.rm_rf(stage)
+end

cases/pan-tilt-head/case.yml

@@ -0,0 +1,148 @@
+---
+schema_version: 1
+name: Pan/Tilt Head
+slug: pan-tilt-head
+generator:
+  sha256: 965260d4d402fd8894f30aa863224e2c9b42dc61a1496f01e2f00b509f9624db
+  created_with: feather-case-wizard
+parameters:
+  top_profile: oled128x64
+  wing_count: 3
+  wing_pitch: 12.25
+  stack_height_override: 38.0
+  generic_component_height: 3.0
+  generic_top_gap: 2.0
+  gps_antenna_height: 6.0
+  gps_top_gap: 5.0
+  oled_component_height: 2.4
+  oled_display_height: 1.5
+  oled_face_gap: 0.8
+  button_a: true
+  button_b: true
+  button_c: true
+  button_reset: false
+  button_projection: 1.5
+  button_cap_size:
+  - 5.0
+  - 3.2
+  button_flange_size:
+  - 6.6
+  - 3.6
+  button_flange_thickness: 0.9
+  button_travel: 0.5
+  button_contact_extension: 0.7
+  battery_enabled: false
+  battery_length: 69.0
+  battery_diameter: 18.0
+  battery_radial_clearance: 0.6
+  battery_end_clearance: 1.0
+  switch_hole_diameter: 12.0
+  switch_hole_compensation: 0.3
+  switch_cap_diameter: 8.0
+  switch_flange_diameter: 16.2
+  switch_body_length: 24.0
+  switch_body_diameter: 12.0
+  switch_wire_allowance: 3.0
+  tripod_insert_enabled: true
+  tripod_insert_length: 6.4
+  tripod_insert_hole_diameter: 8.8
+  tripod_thread_clearance_diameter: 6.8
+  tripod_boss_diameter: 14.0
+  m25_insert_length: 4.0
+  m25_insert_hole_diameter: 3.7
+  m25_screw_clearance: 2.8
+  m25_boss_diameter: 7.0
+  insert_entry_chamfer: 0.6
+  insert_melt_relief: 0.8
+  wall_thickness: 2.4
+  floor_thickness: 2.4
+  lid_thickness: 3.2
+  corner_radius: 4.0
+  board_bottom_clearance: 5.4
+  board_side_clearance: 7.0
+  board_rear_clearance: 20.0
+  usb_board_wall_gap: 20.0
+  lid_lip_depth: 2.4
+  lid_lip_thickness: 1.2
+  fit_clearance: 0.35
+  cutout_min_web: 1.2
+  hole_compensation: 0.2
+  lid_screw_head_diameter: 5.2
+  lid_screw_head_height: 2.5
+  usb_opening_enabled: true
+  usb_guide_enabled: true
+  usb_connector_overhang: 2.0
+  usb_guide_wall_thickness: 1.2
+  usb_guide_end_gap: 1.0
+  usb_opening_width: 12.5
+  usb_opening_height: 7.0
+  usb_opening_radius: 1.5
+  usb_vertical_offset: 0.0
+cutouts:
+- name: Antenna
+  face: left
+  shape: circle
+  horizontal: 30.4
+  z: 31.299999999999997
+  width: 6.5
+  height: 6.5
+  radius: 3.25
+- name: Servo
+  face: rear
+  shape: roundrect
+  horizontal: 20.83
+  z: 35.0
+  width: 10.0
+  height: 5.0
+  radius: 1.25
+- name: Release
+  face: rear
+  shape: circle
+  horizontal: 20.83
+  z: 20.0
+  width: 6.0
+  height: 6.0
+  radius: 3.0
+- name: Power
+  face: front
+  shape: circle
+  horizontal: 20.83
+  z: 31.65
+  width: 8.0
+  height: 8.0
+  radius: 4.0
+outputs:
+  formats:
+  - 3mf
+  coupons: []
+  assembly_exploded_view: 8
+resolved:
+  extra_cutouts:
+  - - left
+    - circle
+    - 30.4
+    - 31.299999999999997
+    - 6.5
+    - 6.5
+    - 3.25
+  - - rear
+    - roundrect
+    - 20.83
+    - 35.0
+    - 10.0
+    - 5.0
+    - 1.25
+  - - rear
+    - circle
+    - 20.83
+    - 20.0
+    - 6.0
+    - 6.0
+    - 3.0
+  - - front
+    - circle
+    - 20.83
+    - 31.65
+    - 8.0
+    - 8.0
+    - 4.0

cases/pan-tilt-head/parameters.json

@@ -0,0 +1,75 @@
+{
+  "parameterSets": {
+    "pan-tilt-head": {
+      "top_profile": "\"oled128x64\"",
+      "wing_count": "3",
+      "wing_pitch": "12.25",
+      "stack_height_override": "38.0",
+      "generic_component_height": "3.0",
+      "generic_top_gap": "2.0",
+      "gps_antenna_height": "6.0",
+      "gps_top_gap": "5.0",
+      "oled_component_height": "2.4",
+      "oled_display_height": "1.5",
+      "oled_face_gap": "0.8",
+      "button_a": "true",
+      "button_b": "true",
+      "button_c": "true",
+      "button_reset": "false",
+      "button_projection": "1.5",
+      "button_cap_size": "[5.0,3.2]",
+      "button_flange_size": "[6.6,3.6]",
+      "button_flange_thickness": "0.9",
+      "button_travel": "0.5",
+      "button_contact_extension": "0.7",
+      "battery_enabled": "false",
+      "battery_length": "69.0",
+      "battery_diameter": "18.0",
+      "battery_radial_clearance": "0.6",
+      "battery_end_clearance": "1.0",
+      "switch_hole_diameter": "12.0",
+      "switch_hole_compensation": "0.3",
+      "switch_cap_diameter": "8.0",
+      "switch_flange_diameter": "16.2",
+      "switch_body_length": "24.0",
+      "switch_body_diameter": "12.0",
+      "switch_wire_allowance": "3.0",
+      "tripod_insert_enabled": "true",
+      "tripod_insert_length": "6.4",
+      "tripod_insert_hole_diameter": "8.8",
+      "tripod_thread_clearance_diameter": "6.8",
+      "tripod_boss_diameter": "14.0",
+      "m25_insert_length": "4.0",
+      "m25_insert_hole_diameter": "3.7",
+      "m25_screw_clearance": "2.8",
+      "m25_boss_diameter": "7.0",
+      "insert_entry_chamfer": "0.6",
+      "insert_melt_relief": "0.8",
+      "wall_thickness": "2.4",
+      "floor_thickness": "2.4",
+      "lid_thickness": "3.2",
+      "corner_radius": "4.0",
+      "board_bottom_clearance": "5.4",
+      "board_side_clearance": "7.0",
+      "board_rear_clearance": "20.0",
+      "usb_board_wall_gap": "20.0",
+      "lid_lip_depth": "2.4",
+      "lid_lip_thickness": "1.2",
+      "fit_clearance": "0.35",
+      "cutout_min_web": "1.2",
+      "hole_compensation": "0.2",
+      "lid_screw_head_diameter": "5.2",
+      "lid_screw_head_height": "2.5",
+      "usb_opening_enabled": "true",
+      "usb_guide_enabled": "true",
+      "usb_connector_overhang": "2.0",
+      "usb_guide_wall_thickness": "1.2",
+      "usb_guide_end_gap": "1.0",
+      "usb_opening_width": "12.5",
+      "usb_opening_height": "7.0",
+      "usb_opening_radius": "1.5",
+      "usb_vertical_offset": "0.0"
+    }
+  },
+  "fileFormatVersion": "1"
+}

cases/pan-tilt-head/source/feather_case.scad

@@ -0,0 +1,965 @@
+/*
+ * Parametric enclosure for the Adafruit ESP32 Feather V2 and FeatherWings.
+ *
+ * Coordinate system:
+ *   X: USB-C wall (0) toward the rear of the case
+ *   Y: non-battery side (0) toward the battery/JST side
+ *   Z: outside bottom (0) upward
+ *
+ * Board coordinates are derived from Adafruit's Eagle PCB files:
+ *   https://github.com/adafruit/Adafruit-ESP32-Feather-V2-PCB
+ *   https://github.com/adafruit/Adafruit-OLED-FeatherWing-PCB
+ */
+
+/* [Output] */
+part = "assembly"; // [assembly,body,lid,buttons,insert_coupon,switch_coupon,fit_coupon]
+exploded_view = 8; // [0:1:20]
+show_references = true;
+
+/* [Stack] */
+top_profile = "generic"; // [generic,gps,oled128x64]
+wing_count = 1; // [1:1:8]
+wing_pitch = 12.25; // [7:0.1:16]
+stack_height_override = 0; // [0:0.1:100]
+generic_component_height = 3; // [0:0.1:30]
+generic_top_gap = 2; // [0.5:0.1:10]
+gps_antenna_height = 6;
+gps_top_gap = 5;
+oled_component_height = 2.4;
+oled_display_height = 1.5;
+oled_face_gap = 0.8;
+
+/* [OLED controls] */
+button_a = true;
+button_b = true;
+button_c = true;
+button_reset = false;
+button_projection = 1.5; // [0.5:0.1:3]
+button_cap_size = [5, 3.2];
+button_flange_size = [6.6, 3.6];
+button_flange_thickness = 0.9;
+button_travel = 0.5;
+button_contact_extension = 0.7;
+
+/* [Battery and switch] */
+battery_enabled = false;
+battery_length = 69;
+battery_diameter = 18;
+battery_radial_clearance = 0.6;
+battery_end_clearance = 1;
+switch_hole_diameter = 12;
+switch_hole_compensation = 0.3;
+switch_cap_diameter = 8;
+switch_flange_diameter = 16.2;
+switch_body_length = 24;
+switch_body_diameter = 12;
+switch_wire_allowance = 3;
+
+/* [Tripod mount] */
+tripod_insert_enabled = false;
+tripod_insert_length = 6.4;
+tripod_insert_hole_diameter = 8.8;
+tripod_thread_clearance_diameter = 6.8;
+tripod_boss_diameter = 14;
+
+/* [M2.5 inserts] */
+m25_insert_length = 4;
+m25_insert_hole_diameter = 3.7;
+m25_screw_clearance = 2.8;
+m25_boss_diameter = 7;
+insert_entry_chamfer = 0.6;
+insert_melt_relief = 0.8;
+
+/* [Shell and fit] */
+wall_thickness = 2.4;
+floor_thickness = 2.4;
+lid_thickness = 3.2;
+corner_radius = 4;
+board_bottom_clearance = 5.4;
+board_side_clearance = 7;
+board_rear_clearance = 4;
+usb_board_wall_gap = 2;
+lid_lip_depth = 2.4;
+lid_lip_thickness = 1.2;
+fit_clearance = 0.35;
+cutout_min_web = 1.2;
+hole_compensation = 0.2;
+lid_screw_head_diameter = 5.2;
+lid_screw_head_height = 2.5;
+
+/* [USB-C opening] */
+usb_opening_enabled = true;
+usb_guide_enabled = true;
+usb_connector_overhang = 2;
+usb_guide_wall_thickness = 1.2;
+usb_guide_end_gap = 1;
+usb_opening_width = 12.5;
+usb_opening_height = 7;
+usb_opening_radius = 1.5;
+usb_vertical_offset = 0;
+
+/* [Custom wall cutouts] */
+// Entry format: [face, shape, u, z, width, height, radius]
+// face: front, rear, left, right. u is Y on front/rear and X on left/right.
+// shape: circle, rect, roundrect, slot. Circle uses width as its diameter.
+extra_cutouts = [];
+
+/* [Calibration] */
+coupon_steps = [-0.3, -0.15, 0, 0.15, 0.3];
+
+$fn = $preview ? 36 : 72;
+eps = 0.02;
+
+// Adafruit Feather mechanical reference, millimetres.
+feather_length = 50.8;
+feather_width = 22.86;
+board_thickness = 1.6;
+mount_x = [2.54, 48.26];
+mount_y = [2.54, 20.32];
+usb_center_y = 11.43;
+
+// Official 128x64 OLED FeatherWing geometry in Feather-board coordinates.
+oled_visible_min = [11.42, 3.78];
+oled_visible_size = [30, 15.3];
+oled_button_a_xy = [4.318, 15.875];
+oled_button_b_xy = [4.318, 11.43];
+oled_button_c_xy = [4.318, 6.985];
+oled_button_reset_xy = [7.366, 20.828];
+
+effective_floor = tripod_insert_enabled
+    ? max(floor_thickness, tripod_insert_length + insert_melt_relief + 1.2)
+    : floor_thickness;
+effective_board_clearance = max(
+    board_bottom_clearance,
+    m25_insert_length + insert_melt_relief + 0.6
+);
+
+board_origin_x = wall_thickness + usb_board_wall_gap;
+board_origin_y = wall_thickness + board_side_clearance;
+board_bottom_z = effective_floor + effective_board_clearance;
+board_top_z = board_bottom_z + board_thickness;
+usb_center_u = board_origin_y + usb_center_y;
+usb_center_z = board_top_z + 1.6 + usb_vertical_offset;
+usb_inner_width = usb_opening_width + hole_compensation;
+usb_inner_height = usb_opening_height + hole_compensation;
+usb_guide_length = max(
+    0,
+    usb_board_wall_gap - usb_connector_overhang - usb_guide_end_gap
+);
+usb_guide_active = usb_opening_enabled && usb_guide_enabled
+    && usb_guide_length > 0;
+usb_reserved_width = usb_inner_width
+    + (usb_guide_active ? 2 * usb_guide_wall_thickness : 0);
+usb_reserved_height = usb_inner_height
+    + (usb_guide_active ? 2 * usb_guide_wall_thickness : 0);
+
+computed_top_pcb_z = board_top_z + wing_count * wing_pitch;
+top_pcb_z = stack_height_override > 0
+    ? board_top_z + stack_height_override
+    : computed_top_pcb_z;
+profile_component_height =
+    top_profile == "gps" ? gps_antenna_height :
+    top_profile == "oled128x64" ? oled_component_height :
+    generic_component_height;
+profile_top_gap =
+    top_profile == "gps" ? gps_top_gap :
+    top_profile == "oled128x64" ? oled_face_gap :
+    generic_top_gap;
+
+partition_y = board_origin_y + feather_width + 1;
+battery_center_y = partition_y + wall_thickness + battery_radial_clearance
+    + battery_diameter / 2;
+battery_start_x = board_origin_x + battery_end_clearance;
+battery_end_x = battery_start_x + battery_length;
+switch_center_x = battery_end_x + max(
+    switch_body_diameter / 2 + 0.8,
+    switch_flange_diameter / 2 + 0.5
+);
+
+case_length_plain = board_origin_x + feather_length
+    + board_rear_clearance + wall_thickness;
+case_length_battery = switch_center_x + switch_flange_diameter / 2
+    + 1.2 + wall_thickness;
+case_length = battery_enabled ? max(case_length_plain, case_length_battery)
+    : case_length_plain;
+
+case_width_plain = board_origin_y + feather_width
+    + board_side_clearance + wall_thickness;
+case_width_battery = battery_center_y + battery_diameter / 2
+    + battery_radial_clearance + wall_thickness;
+case_width = battery_enabled ? max(case_width_plain, case_width_battery)
+    : case_width_plain;
+
+battery_center_z = effective_floor + battery_radial_clearance
+    + battery_diameter / 2;
+switch_center_z = max(
+    effective_floor + switch_flange_diameter / 2 + 1,
+    battery_center_z
+);
+electronics_ceiling_z = top_pcb_z + profile_component_height + profile_top_gap;
+battery_ceiling_z = battery_enabled
+    ? max(
+        battery_center_z + battery_diameter / 2 + battery_radial_clearance,
+        switch_center_z + switch_flange_diameter / 2 + 1
+    )
+    : 0;
+body_height = max(electronics_ceiling_z, battery_ceiling_z);
+
+lid_boss_r = m25_boss_diameter / 2;
+lid_boss_wall_overlap = 0.6;
+lid_boss_xy = [
+    [
+        wall_thickness + lid_boss_r - lid_boss_wall_overlap,
+        wall_thickness + lid_boss_r - lid_boss_wall_overlap
+    ],
+    [
+        case_length - wall_thickness - lid_boss_r + lid_boss_wall_overlap,
+        wall_thickness + lid_boss_r - lid_boss_wall_overlap
+    ],
+    [
+        wall_thickness + lid_boss_r - lid_boss_wall_overlap,
+        case_width - wall_thickness - lid_boss_r + lid_boss_wall_overlap
+    ],
+    [
+        case_length - wall_thickness - lid_boss_r + lid_boss_wall_overlap,
+        case_width - wall_thickness - lid_boss_r + lid_boss_wall_overlap
+    ]
+];
+
+assert(wing_count >= 1, "wing_count must be at least one");
+assert(top_profile == "generic" || top_profile == "gps"
+    || top_profile == "oled128x64", "Unsupported top_profile");
+assert(wall_thickness >= 1.2, "wall_thickness is too small for 0.6 mm FDM");
+assert(lid_lip_thickness >= 1.2, "lid lip needs at least two 0.6 mm lines");
+assert(m25_boss_diameter > m25_insert_hole_diameter + 2,
+    "M2.5 boss does not have enough radial material");
+assert(!tripod_insert_enabled
+    || tripod_boss_diameter > tripod_insert_hole_diameter + 3,
+    "Tripod insert boss does not have enough radial material");
+assert(usb_opening_enabled || !usb_guide_enabled,
+    "USB guide requires the USB opening");
+
+function clamp(v, lo, hi) = min(max(v, lo), hi);
+function cutout_height(entry) = len(entry) > 5 ? entry[5] : entry[4];
+function cutouts_separated(first, second, web) =
+    abs(first[2] - second[2])
+        >= (first[4] + second[4]) / 2 + web
+    || abs(first[3] - second[3])
+        >= (cutout_height(first) + cutout_height(second)) / 2 + web;
+function cutout_clear_of_usb(entry, web) =
+    abs(entry[2] - usb_center_u)
+        >= (entry[4] + usb_reserved_width) / 2 + web
+    || abs(entry[3] - usb_center_z)
+        >= (cutout_height(entry) + usb_reserved_height) / 2 + web;
+
+module validate_cutout_spacing() {
+    if (len(extra_cutouts) > 1)
+        for (first = [0 : len(extra_cutouts) - 2],
+             second = [first + 1 : len(extra_cutouts) - 1])
+            if (extra_cutouts[first][0] == extra_cutouts[second][0])
+                assert(
+                    cutouts_separated(
+                        extra_cutouts[first],
+                        extra_cutouts[second],
+                        cutout_min_web
+                    ),
+                    "Custom cutouts are too close on the same wall"
+                );
+    if (usb_opening_enabled)
+        for (entry = extra_cutouts)
+            if (entry[0] == "front")
+                assert(
+                    cutout_clear_of_usb(entry, cutout_min_web),
+                    "Front cutout is too close to the USB opening or guide"
+                );
+}
+
+module rounded_rect_2d(size, radius) {
+    r = clamp(radius, 0.01, min(size[0], size[1]) / 2 - 0.01);
+    hull() {
+        for (x = [r, size[0] - r], y = [r, size[1] - r])
+            translate([x, y]) circle(r = r);
+    }
+}
+
+module centered_rounded_rect_2d(size, radius) {
+    translate([-size[0] / 2, -size[1] / 2])
+        rounded_rect_2d(size, radius);
+}
+
+module centered_rounded_prism(size, height, radius) {
+    linear_extrude(height = height)
+        centered_rounded_rect_2d(size, radius);
+}
+
+module rounded_box(size, radius) {
+    linear_extrude(height = size[2])
+        rounded_rect_2d([size[0], size[1]], radius);
+}
+
+module insert_pocket(diameter, depth, entry_z, downward = true) {
+    bore_d = diameter + hole_compensation;
+    if (downward) {
+        translate([0, 0, entry_z - depth])
+            cylinder(h = depth + eps, d = bore_d);
+        translate([0, 0, entry_z - insert_entry_chamfer])
+            cylinder(
+                h = insert_entry_chamfer + eps,
+                d1 = bore_d,
+                d2 = bore_d + 2 * insert_entry_chamfer
+            );
+    } else {
+        translate([0, 0, entry_z - eps])
+            cylinder(h = depth + eps, d = bore_d);
+        translate([0, 0, entry_z - eps])
+            cylinder(
+                h = insert_entry_chamfer + eps,
+                d1 = bore_d + 2 * insert_entry_chamfer,
+                d2 = bore_d
+            );
+    }
+}
+
+module face_rounded_cutout(face, u, z, width, height, radius) {
+    r = clamp(radius, 0.01, min(width, height) / 2);
+    depth = wall_thickness + 2 * eps;
+    if (face == "front" || face == "rear") {
+        x0 = face == "front" ? -eps : case_length - wall_thickness - eps;
+        hull()
+            for (yy = [u - width / 2 + r, u + width / 2 - r],
+                 zz = [z - height / 2 + r, z + height / 2 - r])
+                translate([x0, yy, zz])
+                    rotate([0, 90, 0]) cylinder(h = depth, r = r);
+    } else if (face == "left" || face == "right") {
+        y0 = face == "left" ? -eps : case_width - wall_thickness - eps;
+        hull()
+            for (xx = [u - width / 2 + r, u + width / 2 - r],
+                 zz = [z - height / 2 + r, z + height / 2 - r])
+                translate([xx, y0, zz])
+                    rotate([-90, 0, 0]) cylinder(h = depth, r = r);
+    }
+}
+
+module face_circle_cutout(face, u, z, diameter) {
+    depth = wall_thickness + 2 * eps;
+    if (face == "front")
+        translate([-eps, u, z])
+            rotate([0, 90, 0]) cylinder(h = depth, d = diameter);
+    else if (face == "rear")
+        translate([case_length - wall_thickness - eps, u, z])
+            rotate([0, 90, 0]) cylinder(h = depth, d = diameter);
+    else if (face == "left")
+        translate([u, -eps, z])
+            rotate([-90, 0, 0]) cylinder(h = depth, d = diameter);
+    else if (face == "right")
+        translate([u, case_width - wall_thickness - eps, z])
+            rotate([-90, 0, 0]) cylinder(h = depth, d = diameter);
+}
+
+module x_rounded_prism(x, length, u, z, width, height, radius) {
+    r = clamp(radius, 0.01, min(width, height) / 2 - 0.01);
+    hull()
+        for (yy = [u - width / 2 + r, u + width / 2 - r],
+             zz = [z - height / 2 + r, z + height / 2 - r])
+            translate([x, yy, zz])
+                rotate([0, 90, 0]) cylinder(h = length, r = r);
+}
+
+module usb_guide_shell() {
+    outer_width = usb_inner_width + 2 * usb_guide_wall_thickness;
+    outer_height = usb_inner_height + 2 * usb_guide_wall_thickness;
+    difference() {
+        x_rounded_prism(
+            wall_thickness - eps,
+            usb_guide_length + 2 * eps,
+            usb_center_u,
+            usb_center_z,
+            outer_width,
+            outer_height,
+            usb_opening_radius + usb_guide_wall_thickness
+        );
+        x_rounded_prism(
+            wall_thickness - 2 * eps,
+            usb_guide_length + 4 * eps,
+            usb_center_u,
+            usb_center_z,
+            usb_inner_width,
+            usb_inner_height,
+            usb_opening_radius
+        );
+    }
+}
+
+module custom_wall_cutout(entry) {
+    face = entry[0];
+    shape = entry[1];
+    u = entry[2];
+    z = entry[3];
+    width = entry[4];
+    height = len(entry) > 5 ? entry[5] : width;
+    radius = len(entry) > 6 ? entry[6] : min(width, height) / 2;
+    assert(face == "front" || face == "rear"
+        || face == "left" || face == "right", "Invalid cutout face");
+    assert(shape == "circle" || shape == "rect"
+        || shape == "roundrect" || shape == "slot", "Invalid cutout shape");
+    assert(z - height / 2 >= effective_floor,
+        "Cutout intersects the floor");
+    assert(z + height / 2 <= body_height - lid_lip_depth,
+        "Cutout intersects the lid locating lip");
+    assert(
+        (face == "front" || face == "rear")
+            ? u - width / 2 >= 0 && u + width / 2 <= case_width
+            : u - width / 2 >= 0 && u + width / 2 <= case_length,
+        "Cutout extends beyond its wall"
+    );
+
+    if (shape == "circle")
+        face_circle_cutout(face, u, z, width);
+    else
+        face_rounded_cutout(
+            face, u, z, width, height,
+            shape == "rect" ? 0.02 :
+            shape == "slot" ? min(width, height) / 2 : radius
+        );
+}
+
+module board_standoffs() {
+    for (mx = mount_x, my = mount_y)
+        translate([
+            board_origin_x + mx,
+            board_origin_y + my,
+            effective_floor - eps
+        ])
+            cylinder(
+                h = effective_board_clearance + eps,
+                d = m25_boss_diameter
+            );
+}
+
+module lid_bosses() {
+    for (p = lid_boss_xy)
+        translate([p[0], p[1], effective_floor - eps])
+            cylinder(
+                h = body_height - effective_floor + eps,
+                d = m25_boss_diameter
+            );
+}
+
+module battery_cradle() {
+    partition_height = min(
+        body_height - lid_lip_depth - 0.5,
+        battery_center_z + battery_diameter / 2 + 1.5
+    );
+    rib_width = 2.4;
+    rib_positions = [
+        battery_start_x + 4,
+        (battery_start_x + battery_end_x) / 2,
+        battery_end_x - 4
+    ];
+
+    // Board/battery partition, with a lead-routing notch near the JST end.
+    difference() {
+        translate([wall_thickness, partition_y, effective_floor - eps])
+            cube([
+                battery_end_x - wall_thickness + battery_end_clearance,
+                wall_thickness,
+                partition_height - effective_floor + eps
+            ]);
+        translate([
+            board_origin_x + 6.5,
+            partition_y - eps,
+            effective_floor + 1.5
+        ])
+            cube([9, wall_thickness + 2 * eps, 6]);
+    }
+
+    // Three low curved ribs cradle the protected cylindrical pack.
+    for (x = rib_positions)
+        difference() {
+            translate([
+                x - rib_width / 2,
+                battery_center_y - battery_diameter / 2
+                    - battery_radial_clearance,
+                effective_floor - eps
+            ])
+                cube([
+                    rib_width,
+                    battery_diameter + 2 * battery_radial_clearance,
+                    battery_diameter / 2 + battery_radial_clearance + eps
+                ]);
+            translate([x - rib_width, battery_center_y, battery_center_z])
+                rotate([0, 90, 0])
+                    cylinder(
+                        h = rib_width * 2,
+                        d = battery_diameter + 2 * battery_radial_clearance
+                    );
+        }
+
+    // End stops remain below the cell center so the lid can remove vertically.
+    for (x = [
+        battery_start_x - battery_end_clearance - wall_thickness,
+        battery_end_x + battery_end_clearance
+    ])
+        translate([
+            x,
+            battery_center_y - battery_diameter / 2 - battery_radial_clearance,
+            effective_floor - eps
+        ])
+            cube([
+                wall_thickness,
+                battery_diameter + 2 * battery_radial_clearance,
+                battery_diameter / 2 + 1 + eps
+            ]);
+
+    // Rear cross-strip separates the side-mounted switch body from the cell.
+    translate([
+        battery_end_x + battery_end_clearance,
+        partition_y,
+        effective_floor - eps
+    ])
+        cube([
+            case_length - wall_thickness - battery_end_x - battery_end_clearance,
+            case_width - wall_thickness - partition_y,
+            min(body_height - effective_floor, switch_center_z
+                + switch_body_diameter / 2 + switch_wire_allowance
+                - effective_floor) + eps
+        ]);
+}
+
+module body_positive() {
+    union() {
+        difference() {
+            rounded_box([case_length, case_width, body_height], corner_radius);
+            translate([wall_thickness, wall_thickness, effective_floor])
+                rounded_box([
+                    case_length - 2 * wall_thickness,
+                    case_width - 2 * wall_thickness,
+                    body_height - effective_floor + eps
+                ], max(0.6, corner_radius - wall_thickness));
+        }
+        board_standoffs();
+        lid_bosses();
+        if (battery_enabled)
+            battery_cradle();
+        if (tripod_insert_enabled)
+            translate([case_length / 2, case_width / 2, 0])
+                cylinder(h = effective_floor, d = tripod_boss_diameter);
+        if (usb_guide_active)
+            usb_guide_shell();
+    }
+}
+
+module body_cutouts() {
+    // Board mounting insert pockets, loaded from above before the Feather.
+    for (mx = mount_x, my = mount_y)
+        translate([board_origin_x + mx, board_origin_y + my, 0])
+            insert_pocket(
+                m25_insert_hole_diameter,
+                m25_insert_length + insert_melt_relief,
+                board_bottom_z
+            );
+
+    // Lid insert pockets, loaded from the top of the body.
+    for (p = lid_boss_xy)
+        translate([p[0], p[1], 0])
+            insert_pocket(
+                m25_insert_hole_diameter,
+                m25_insert_length + insert_melt_relief,
+                body_height
+            );
+
+    // USB-C cable opening. Connector center is from the official ESP32 V2 PCB.
+    if (usb_opening_enabled)
+        face_rounded_cutout(
+            "front",
+            usb_center_u,
+            usb_center_z,
+            usb_inner_width,
+            usb_inner_height,
+            usb_opening_radius
+        );
+
+    if (battery_enabled) {
+        face_circle_cutout(
+            "right",
+            switch_center_x,
+            switch_center_z,
+            switch_hole_diameter + switch_hole_compensation
+        );
+        // Clear the switch body and its prewired terminals through the rear bay.
+        translate([
+            switch_center_x,
+            case_width - wall_thickness + eps,
+            switch_center_z
+        ])
+            rotate([90, 0, 0])
+                cylinder(
+                    h = switch_body_length + switch_wire_allowance
+                        + wall_thickness + eps,
+                    d = switch_body_diameter + 2 * fit_clearance
+                );
+    }
+
+    if (tripod_insert_enabled) {
+        translate([case_length / 2, case_width / 2, 0]) {
+            translate([0, 0, -eps])
+                cylinder(
+                    h = effective_floor + 2 * eps,
+                    d = tripod_thread_clearance_diameter + hole_compensation
+                );
+            insert_pocket(
+                tripod_insert_hole_diameter,
+                tripod_insert_length + insert_melt_relief,
+                effective_floor
+            );
+        }
+    }
+
+    for (entry = extra_cutouts)
+        custom_wall_cutout(entry);
+}
+
+module body() {
+    difference() {
+        body_positive();
+        body_cutouts();
+    }
+}
+
+module lid_plate_positive() {
+    union() {
+        rounded_box([case_length, case_width, lid_thickness], corner_radius);
+        // Inset rim: exported pointing upward so the outer lid face prints flat.
+        translate([
+            wall_thickness + fit_clearance,
+            wall_thickness + fit_clearance,
+            lid_thickness
+        ])
+            linear_extrude(height = lid_lip_depth)
+                difference() {
+                    rounded_rect_2d([
+                        case_length - 2 * (wall_thickness + fit_clearance),
+                        case_width - 2 * (wall_thickness + fit_clearance)
+                    ], max(0.6, corner_radius - wall_thickness));
+                    translate([lid_lip_thickness, lid_lip_thickness])
+                        rounded_rect_2d([
+                            case_length - 2 * (
+                                wall_thickness + fit_clearance
+                                + lid_lip_thickness
+                            ),
+                            case_width - 2 * (
+                                wall_thickness + fit_clearance
+                                + lid_lip_thickness
+                            )
+                        ], max(0.5, corner_radius - wall_thickness
+                            - lid_lip_thickness));
+                }
+    }
+}
+
+module beveled_oled_window() {
+    inner_size = oled_visible_size;
+    outer_size = [oled_visible_size[0] + 3, oled_visible_size[1] + 3];
+    center = [
+        board_origin_x + oled_visible_min[0] + oled_visible_size[0] / 2,
+        board_origin_y + oled_visible_min[1] + oled_visible_size[1] / 2
+    ];
+    hull() {
+        translate([center[0], center[1], -eps])
+            linear_extrude(height = eps)
+                centered_rounded_rect_2d(outer_size, 1.5);
+        translate([center[0], center[1], lid_thickness - eps])
+            linear_extrude(height = 2 * eps)
+                centered_rounded_rect_2d(inner_size, 0.8);
+    }
+}
+
+module oled_button_lid_cutout(xy) {
+    center = [board_origin_x + xy[0], board_origin_y + xy[1]];
+    shaft_size = [
+        button_cap_size[0] + fit_clearance * 2,
+        button_cap_size[1] + fit_clearance * 2
+    ];
+    recess_size = [
+        button_flange_size[0] + fit_clearance * 2,
+        button_flange_size[1] + fit_clearance * 2
+    ];
+    recess_depth = button_flange_thickness + button_travel;
+    translate([center[0], center[1], -eps])
+        centered_rounded_prism(
+            shaft_size,
+            lid_thickness + 2 * eps,
+            shaft_size[1] / 2
+        );
+    translate([center[0], center[1], lid_thickness - recess_depth])
+        centered_rounded_prism(
+            recess_size,
+            recess_depth + lid_lip_depth + eps,
+            recess_size[1] / 2
+        );
+}
+
+module lid_cutouts() {
+    // Through holes plus shallow counterbores for flush M2.5 socket heads.
+    for (p = lid_boss_xy) {
+        translate([p[0], p[1], -eps])
+            cylinder(
+                h = lid_thickness + lid_lip_depth + 2 * eps,
+                d = m25_screw_clearance + hole_compensation
+            );
+        translate([p[0], p[1], -eps])
+            cylinder(
+                h = lid_screw_head_height + eps,
+                d = lid_screw_head_diameter + hole_compensation
+            );
+    }
+
+    if (top_profile == "oled128x64") {
+        beveled_oled_window();
+        if (button_a) oled_button_lid_cutout(oled_button_a_xy);
+        if (button_b) oled_button_lid_cutout(oled_button_b_xy);
+        if (button_c) oled_button_lid_cutout(oled_button_c_xy);
+        if (button_reset) oled_button_lid_cutout(oled_button_reset_xy);
+    }
+}
+
+module lid() {
+    difference() {
+        lid_plate_positive();
+        lid_cutouts();
+    }
+}
+
+module one_oled_button() {
+    recess_depth = button_flange_thickness + button_travel;
+    stem_height = lid_thickness - recess_depth + button_projection;
+    // Print outer cap face down. The flange and contact nub build upward.
+    centered_rounded_prism(
+        button_cap_size,
+        stem_height,
+        button_cap_size[1] / 2
+    );
+    translate([0, 0, stem_height])
+        centered_rounded_prism(
+            button_flange_size,
+            button_flange_thickness,
+            button_flange_size[1] / 2
+        );
+    translate([0, 0, stem_height + button_flange_thickness])
+        cylinder(h = button_contact_extension, d = 3);
+}
+
+module buttons() {
+    enabled = [
+        button_a,
+        button_b,
+        button_c,
+        button_reset
+    ];
+    count_enabled = len([for (v = enabled) if (v) 1]);
+    if (count_enabled == 0)
+        echo("No OLED buttons are enabled.");
+    for (i = [0 : len(enabled) - 1])
+        if (enabled[i])
+            translate([i * (button_flange_size[0] + 3), 0, 0])
+                one_oled_button();
+}
+
+module reference_board() {
+    color([0.05, 0.25, 0.55, 0.75])
+        translate([board_origin_x, board_origin_y, board_bottom_z])
+            rounded_box([feather_length, feather_width, board_thickness], 2.54);
+    color([0.12, 0.45, 0.75, 0.45])
+        for (i = [1 : wing_count])
+            translate([
+                board_origin_x,
+                board_origin_y,
+                board_top_z + i * wing_pitch - board_thickness
+            ])
+                rounded_box(
+                    [feather_length, feather_width, board_thickness], 2.54
+                );
+}
+
+module reference_top_feature() {
+    if (top_profile == "gps")
+        color([0.92, 0.78, 0.35, 0.8])
+            translate([
+                board_origin_x + 31,
+                board_origin_y + (feather_width - 15) / 2,
+                top_pcb_z
+            ])
+                cube([15, 15, gps_antenna_height]);
+    else if (top_profile == "oled128x64") {
+        color([0.12, 0.12, 0.12, 0.9])
+            translate([
+                board_origin_x + oled_visible_min[0],
+                board_origin_y + oled_visible_min[1],
+                top_pcb_z
+            ])
+                cube([
+                    oled_visible_size[0],
+                    oled_visible_size[1],
+                    oled_display_height
+                ]);
+        color([0.6, 0.6, 0.6, 0.9])
+            for (xy = [
+                oled_button_a_xy,
+                oled_button_b_xy,
+                oled_button_c_xy,
+                oled_button_reset_xy
+            ])
+                translate([
+                    board_origin_x + xy[0],
+                    board_origin_y + xy[1],
+                    top_pcb_z
+                ])
+                    cylinder(h = 1.6, d = 2.1);
+    } else
+        color([0.3, 0.65, 0.35, 0.6])
+            translate([
+                board_origin_x + 10,
+                board_origin_y + 4,
+                top_pcb_z
+            ])
+                cube([
+                    feather_length - 20,
+                    feather_width - 8,
+                    generic_component_height
+                ]);
+}
+
+module reference_battery_and_switch() {
+    if (battery_enabled) {
+        color([0.35, 0.18, 0.55, 0.75])
+            translate([battery_start_x, battery_center_y, battery_center_z])
+                rotate([0, 90, 0])
+                    cylinder(h = battery_length, d = battery_diameter);
+        color([0.8, 0.15, 0.1, 0.65])
+            translate([
+                switch_center_x,
+                case_width - wall_thickness,
+                switch_center_z
+            ])
+                rotate([90, 0, 0]) {
+                    cylinder(h = switch_body_length, d = switch_body_diameter);
+                    translate([0, 0, -1.5])
+                        cylinder(h = 1.5, d = switch_flange_diameter);
+                    translate([0, 0, -3])
+                        cylinder(h = 3, d = switch_cap_diameter);
+                }
+    }
+}
+
+module assembly() {
+    color([0.82, 0.84, 0.88, 1]) body();
+    if ($preview && show_references) {
+        reference_board();
+        reference_top_feature();
+        reference_battery_and_switch();
+    }
+    // Printable lid is mirrored into its installed orientation and exploded up.
+    color([0.92, 0.92, 0.95, 0.88])
+        translate([0, case_width, body_height + lid_thickness + exploded_view])
+            rotate([180, 0, 0])
+                lid();
+}
+
+module coupon_hole(x, y, diameter, depth) {
+    translate([x, y, -eps]) cylinder(h = depth + 2 * eps, d = diameter);
+}
+
+module insert_coupon() {
+    spacing = 15;
+    coupon_length = spacing * len(coupon_steps) + 8;
+    coupon_width = 32;
+    coupon_height = max(
+        m25_insert_length + insert_melt_relief + 1.2,
+        tripod_insert_length + insert_melt_relief + 1.2
+    );
+    difference() {
+        rounded_box([coupon_length, coupon_width, coupon_height], 3);
+        for (i = [0 : len(coupon_steps) - 1]) {
+            x = 7 + i * spacing;
+            coupon_hole(
+                x, 8,
+                m25_insert_hole_diameter + coupon_steps[i],
+                m25_insert_length + insert_melt_relief
+            );
+            coupon_hole(
+                x, 23,
+                tripod_insert_hole_diameter + coupon_steps[i],
+                tripod_insert_length + insert_melt_relief
+            );
+        }
+    }
+}
+
+module switch_coupon() {
+    spacing = 18;
+    coupon_length = spacing * len(coupon_steps) + 6;
+    coupon_width = 24;
+    coupon_height = wall_thickness;
+    difference() {
+        rounded_box([coupon_length, coupon_width, coupon_height], 3);
+        for (i = [0 : len(coupon_steps) - 1])
+            translate([6 + i * spacing, coupon_width / 2, -eps])
+                cylinder(
+                    h = coupon_height + 2 * eps,
+                    d = switch_hole_diameter + coupon_steps[i]
+                );
+    }
+}
+
+module fit_coupon() {
+    segment_length = 34;
+    base_width = 16;
+    base_height = 6;
+    cavity_size = [segment_length - 8, base_width - 8];
+    male_size = [
+        cavity_size[0] - 2 * fit_clearance,
+        cavity_size[1] - 2 * fit_clearance
+    ];
+    difference() {
+        rounded_box([segment_length, base_width, base_height], 2);
+        translate([4, 4, 2])
+            cube([segment_length - 8, base_width - 8, base_height]);
+    }
+    translate([segment_length + 5, 0, 0])
+        union() {
+            cube([segment_length, base_width, lid_thickness]);
+            translate([
+                4 + fit_clearance,
+                4 + fit_clearance,
+                lid_thickness - eps
+            ])
+                linear_extrude(height = lid_lip_depth + eps)
+                    difference() {
+                        rounded_rect_2d(male_size, 1);
+                        translate([lid_lip_thickness, lid_lip_thickness])
+                            rounded_rect_2d([
+                                male_size[0] - 2 * lid_lip_thickness,
+                                male_size[1] - 2 * lid_lip_thickness
+                            ], 0.5);
+                    }
+        }
+}
+
+validate_cutout_spacing();
+
+if (part == "assembly")
+    assembly();
+else if (part == "body")
+    body();
+else if (part == "lid")
+    lid();
+else if (part == "buttons")
+    buttons();
+else if (part == "insert_coupon")
+    insert_coupon();
+else if (part == "switch_coupon")
+    switch_coupon();
+else if (part == "fit_coupon")
+    fit_coupon();
+else
+    assert(false, str("Unknown part: ", part));

cases/pan-tilt-head/source/render_stl_previews.py

@@ -0,0 +1,127 @@
+"""Render six inspection views of an STL using Blender.
+
+Usage:
+    blender --background --python tools/render_stl_previews.py -- \
+        input.stl output-directory basename [comma-separated-views]
+"""
+
+import os
+import sys
+
+import bpy
+from mathutils import Vector
+
+
+def arguments():
+    args = sys.argv[sys.argv.index("--") + 1 :]
+    if len(args) not in (3, 4):
+        raise SystemExit(
+            "expected: input.stl output-directory basename [comma-separated-views]"
+        )
+    requested_views = args[3].split(",") if len(args) == 4 else None
+    return args[0], args[1], args[2], requested_views
+
+
+def look_at(camera, target):
+    direction = Vector(target) - camera.location
+    camera.rotation_euler = direction.to_track_quat("-Z", "Y").to_euler()
+
+
+def render_view(camera, center, span, name, direction, output_dir, basename):
+    distance = span * 2.2
+    camera.location = Vector(center) + Vector(direction).normalized() * distance
+    look_at(camera, center)
+    camera.data.type = "ORTHO"
+    camera.data.ortho_scale = span * 1.35
+    bpy.context.scene.render.filepath = os.path.join(
+        output_dir, f"{basename}_{name}.png"
+    )
+    bpy.ops.render.render(write_still=True)
+
+
+def main():
+    input_path, output_dir, basename, requested_views = arguments()
+    os.makedirs(output_dir, exist_ok=True)
+
+    bpy.ops.wm.read_factory_settings(use_empty=True)
+    bpy.ops.wm.stl_import(filepath=os.path.abspath(input_path))
+    model = bpy.context.selected_objects[0]
+    model.name = "Feather case"
+
+    material = bpy.data.materials.new("Case material")
+    material.diffuse_color = (0.16, 0.42, 0.72, 1.0)
+    material.metallic = 0.0
+    material.roughness = 0.45
+    model.data.materials.append(material)
+
+    corners = [model.matrix_world @ Vector(corner) for corner in model.bound_box]
+    mins = Vector([min(v[i] for v in corners) for i in range(3)])
+    maxs = Vector([max(v[i] for v in corners) for i in range(3)])
+    center = (mins + maxs) / 2
+    span = max(maxs - mins)
+
+    world = bpy.data.worlds.new("Inspection world")
+    world.use_nodes = True
+    world.node_tree.nodes["Background"].inputs["Color"].default_value = (
+        0.035,
+        0.04,
+        0.05,
+        1,
+    )
+    world.node_tree.nodes["Background"].inputs["Strength"].default_value = 0.5
+    bpy.context.scene.world = world
+
+    camera_data = bpy.data.cameras.new("Camera")
+    camera = bpy.data.objects.new("Camera", camera_data)
+    bpy.context.collection.objects.link(camera)
+    bpy.context.scene.camera = camera
+
+    key_data = bpy.data.lights.new("Key", type="AREA")
+    key_data.energy = 900
+    key_data.shape = "DISK"
+    key_data.size = span
+    key = bpy.data.objects.new("Key", key_data)
+    key.location = center + Vector((span, -span, span * 1.5))
+    bpy.context.collection.objects.link(key)
+
+    fill_data = bpy.data.lights.new("Fill", type="AREA")
+    fill_data.energy = 500
+    fill_data.size = span
+    fill = bpy.data.objects.new("Fill", fill_data)
+    fill.location = center + Vector((-span, span, span))
+    bpy.context.collection.objects.link(fill)
+
+    scene = bpy.context.scene
+    scene.render.engine = "BLENDER_WORKBENCH"
+    scene.render.resolution_x = 800
+    scene.render.resolution_y = 600
+    scene.render.resolution_percentage = 100
+    scene.render.image_settings.file_format = "PNG"
+    scene.render.film_transparent = False
+    scene.display.shading.light = "STUDIO"
+    scene.display.shading.color_type = "MATERIAL"
+    scene.display.shading.show_shadows = True
+    scene.display.shading.show_cavity = True
+    scene.display.shading.cavity_type = "BOTH"
+    scene.display.shading.curvature_ridge_factor = 1.5
+    scene.display.shading.curvature_valley_factor = 1.2
+
+    views = {
+        "iso": (1, -1, 0.8),
+        "front": (-1, 0, 0),
+        "back": (1, 0, 0),
+        "left": (0, -1, 0),
+        "right": (0, 1, 0),
+        "top": (0, 0, 1),
+    }
+    selected = requested_views or list(views)
+    unknown = sorted(set(selected) - set(views))
+    if unknown:
+        raise SystemExit(f"unknown views: {', '.join(unknown)}")
+    for name in selected:
+        direction = views[name]
+        render_view(camera, center, span, name, direction, output_dir, basename)
+
+
+if __name__ == "__main__":
+    main()

feather_case.scad

@@ -19,13 +19,14 @@ show_references = true;
 /* [Stack] */
 top_profile = "generic"; // [generic,gps,oled128x64]
 wing_count = 1; // [1:1:8]
-wing_pitch = 11; // [7:0.1:16]
+wing_pitch = 12.25; // [7:0.1:16]
 stack_height_override = 0; // [0:0.1:100]
 generic_component_height = 3; // [0:0.1:30]
 generic_top_gap = 2; // [0.5:0.1:10]
-gps_antenna_height = 4;
+gps_antenna_height = 6;
 gps_top_gap = 5;
 oled_component_height = 2.4;
+oled_display_height = 1.5;
 oled_face_gap = 0.8;
 
 /* [OLED controls] */
@@ -77,15 +78,21 @@ corner_radius = 4;
 board_bottom_clearance = 5.4;
 board_side_clearance = 7;
 board_rear_clearance = 4;
-usb_board_wall_gap = 1.2;
+usb_board_wall_gap = 2;
 lid_lip_depth = 2.4;
 lid_lip_thickness = 1.2;
 fit_clearance = 0.35;
+cutout_min_web = 1.2;
 hole_compensation = 0.2;
 lid_screw_head_diameter = 5.2;
 lid_screw_head_height = 2.5;
 
 /* [USB-C opening] */
+usb_opening_enabled = true;
+usb_guide_enabled = true;
+usb_connector_overhang = 2;
+usb_guide_wall_thickness = 1.2;
+usb_guide_end_gap = 1;
 usb_opening_width = 12.5;
 usb_opening_height = 7;
 usb_opening_radius = 1.5;
@@ -131,6 +138,20 @@ board_origin_x = wall_thickness + usb_board_wall_gap;
 board_origin_y = wall_thickness + board_side_clearance;
 board_bottom_z = effective_floor + effective_board_clearance;
 board_top_z = board_bottom_z + board_thickness;
+usb_center_u = board_origin_y + usb_center_y;
+usb_center_z = board_top_z + 1.6 + usb_vertical_offset;
+usb_inner_width = usb_opening_width + hole_compensation;
+usb_inner_height = usb_opening_height + hole_compensation;
+usb_guide_length = max(
+    0,
+    usb_board_wall_gap - usb_connector_overhang - usb_guide_end_gap
+);
+usb_guide_active = usb_opening_enabled && usb_guide_enabled
+    && usb_guide_length > 0;
+usb_reserved_width = usb_inner_width
+    + (usb_guide_active ? 2 * usb_guide_wall_thickness : 0);
+usb_reserved_height = usb_inner_height
+    + (usb_guide_active ? 2 * usb_guide_wall_thickness : 0);
 
 computed_top_pcb_z = board_top_z + wing_count * wing_pitch;
 top_pcb_z = stack_height_override > 0
@@ -215,8 +236,43 @@ assert(m25_boss_diameter > m25_insert_hole_diameter + 2,
 assert(!tripod_insert_enabled
     || tripod_boss_diameter > tripod_insert_hole_diameter + 3,
     "Tripod insert boss does not have enough radial material");
+assert(usb_opening_enabled || !usb_guide_enabled,
+    "USB guide requires the USB opening");
 
 function clamp(v, lo, hi) = min(max(v, lo), hi);
+function cutout_height(entry) = len(entry) > 5 ? entry[5] : entry[4];
+function cutouts_separated(first, second, web) =
+    abs(first[2] - second[2])
+        >= (first[4] + second[4]) / 2 + web
+    || abs(first[3] - second[3])
+        >= (cutout_height(first) + cutout_height(second)) / 2 + web;
+function cutout_clear_of_usb(entry, web) =
+    abs(entry[2] - usb_center_u)
+        >= (entry[4] + usb_reserved_width) / 2 + web
+    || abs(entry[3] - usb_center_z)
+        >= (cutout_height(entry) + usb_reserved_height) / 2 + web;
+
+module validate_cutout_spacing() {
+    if (len(extra_cutouts) > 1)
+        for (first = [0 : len(extra_cutouts) - 2],
+             second = [first + 1 : len(extra_cutouts) - 1])
+            if (extra_cutouts[first][0] == extra_cutouts[second][0])
+                assert(
+                    cutouts_separated(
+                        extra_cutouts[first],
+                        extra_cutouts[second],
+                        cutout_min_web
+                    ),
+                    "Custom cutouts are too close on the same wall"
+                );
+    if (usb_opening_enabled)
+        for (entry = extra_cutouts)
+            if (entry[0] == "front")
+                assert(
+                    cutout_clear_of_usb(entry, cutout_min_web),
+                    "Front cutout is too close to the USB opening or guide"
+                );
+}
 
 module rounded_rect_2d(size, radius) {
     r = clamp(radius, 0.01, min(size[0], size[1]) / 2 - 0.01);
@@ -300,6 +356,40 @@ module face_circle_cutout(face, u, z, diameter) {
             rotate([-90, 0, 0]) cylinder(h = depth, d = diameter);
 }
 
+module x_rounded_prism(x, length, u, z, width, height, radius) {
+    r = clamp(radius, 0.01, min(width, height) / 2 - 0.01);
+    hull()
+        for (yy = [u - width / 2 + r, u + width / 2 - r],
+             zz = [z - height / 2 + r, z + height / 2 - r])
+            translate([x, yy, zz])
+                rotate([0, 90, 0]) cylinder(h = length, r = r);
+}
+
+module usb_guide_shell() {
+    outer_width = usb_inner_width + 2 * usb_guide_wall_thickness;
+    outer_height = usb_inner_height + 2 * usb_guide_wall_thickness;
+    difference() {
+        x_rounded_prism(
+            wall_thickness - eps,
+            usb_guide_length + 2 * eps,
+            usb_center_u,
+            usb_center_z,
+            outer_width,
+            outer_height,
+            usb_opening_radius + usb_guide_wall_thickness
+        );
+        x_rounded_prism(
+            wall_thickness - 2 * eps,
+            usb_guide_length + 4 * eps,
+            usb_center_u,
+            usb_center_z,
+            usb_inner_width,
+            usb_inner_height,
+            usb_opening_radius
+        );
+    }
+}
+
 module custom_wall_cutout(entry) {
     face = entry[0];
     shape = entry[1];
@@ -454,6 +544,8 @@ module body_positive() {
         if (tripod_insert_enabled)
             translate([case_length / 2, case_width / 2, 0])
                 cylinder(h = effective_floor, d = tripod_boss_diameter);
+        if (usb_guide_active)
+            usb_guide_shell();
     }
 }
 
@@ -477,13 +569,13 @@ module body_cutouts() {
             );
 
     // USB-C cable opening. Connector center is from the official ESP32 V2 PCB.
-    usb_center_z = board_top_z + 1.6 + usb_vertical_offset;
+    if (usb_opening_enabled)
         face_rounded_cutout(
             "front",
-        board_origin_y + usb_center_y,
+            usb_center_u,
             usb_center_z,
-        usb_opening_width + hole_compensation,
+            usb_inner_width,
-        usb_opening_height + hole_compensation,
+            usb_inner_height,
             usb_opening_radius
         );
 
@@ -708,7 +800,7 @@ module reference_top_feature() {
                 cube([
                     oled_visible_size[0],
                     oled_visible_size[1],
-                    oled_component_height
+                    oled_display_height
                 ]);
         color([0.6, 0.6, 0.6, 0.9])
             for (xy = [
@@ -853,6 +945,8 @@ module fit_coupon() {
         }
 }
 
+validate_cutout_spacing();
+
 if (part == "assembly")
     assembly();
 else if (part == "body")

lib/feather_case_wizard.rb

@@ -11,6 +11,7 @@ require "yaml"
 
 require "highline"
 
+require_relative "feather_case_wizard/prompting_ui"
 require_relative "feather_case_wizard/config"
 require_relative "feather_case_wizard/toolchain"
 require_relative "feather_case_wizard/package_builder"
@@ -23,4 +24,3 @@ module FeatherCaseWizard
   MODEL_SOURCE = ROOT.join("feather_case.scad").freeze
   RENDERER_SOURCE = ROOT.join("tools/render_stl_previews.py").freeze
 end
-

lib/feather_case_wizard/cli.rb

@@ -5,18 +5,18 @@ module FeatherCaseWizard
     def initialize(ui: HighLine.new, cases_root: CASES_ROOT,
                    model_source: MODEL_SOURCE, renderer_source: RENDERER_SOURCE,
                    toolchain: Toolchain.new)
-      @ui = ui
+      @ui = PromptingUI.wrap(ui)
       @cases_root = Pathname(cases_root)
       @model_source = Pathname(model_source)
       @renderer_source = Pathname(renderer_source)
       @toolchain = toolchain
-      @wizard = Wizard.new(ui: ui)
+      @wizard = Wizard.new(ui: @ui)
     end
 
     def run
       @ui.say(@ui.color("Feather Case Wizard", :bold))
       loop do
-        action = @ui.choose("\nWhat would you like to do?") do |menu|
+        action = @ui.choose("What would you like to do?") do |menu|
           menu.choice("Create a new case") { :create }
           menu.choice("Edit an existing case") { :edit }
           menu.choice("Rebuild an existing case") { :rebuild }

lib/feather_case_wizard/config.rb

@@ -14,13 +14,14 @@ module FeatherCaseWizard
     DEFAULT_PARAMETERS = {
       "top_profile" => "generic",
       "wing_count" => 1,
-      "wing_pitch" => 11.0,
+      "wing_pitch" => 12.25,
       "stack_height_override" => 0.0,
       "generic_component_height" => 3.0,
       "generic_top_gap" => 2.0,
-      "gps_antenna_height" => 4.0,
+      "gps_antenna_height" => 6.0,
       "gps_top_gap" => 5.0,
       "oled_component_height" => 2.4,
+      "oled_display_height" => 1.5,
       "oled_face_gap" => 0.8,
       "button_a" => true,
       "button_b" => true,
@@ -62,13 +63,19 @@ module FeatherCaseWizard
       "board_bottom_clearance" => 5.4,
       "board_side_clearance" => 7.0,
       "board_rear_clearance" => 4.0,
-      "usb_board_wall_gap" => 1.2,
+      "usb_board_wall_gap" => 2.0,
       "lid_lip_depth" => 2.4,
       "lid_lip_thickness" => 1.2,
       "fit_clearance" => 0.35,
+      "cutout_min_web" => 1.2,
       "hole_compensation" => 0.2,
       "lid_screw_head_diameter" => 5.2,
       "lid_screw_head_height" => 2.5,
+      "usb_opening_enabled" => true,
+      "usb_guide_enabled" => true,
+      "usb_connector_overhang" => 2.0,
+      "usb_guide_wall_thickness" => 1.2,
+      "usb_guide_end_gap" => 1.0,
       "usb_opening_width" => 12.5,
       "usb_opening_height" => 7.0,
       "usb_opening_radius" => 1.5,
@@ -77,11 +84,12 @@ module FeatherCaseWizard
 
     ADVANCED_FIELDS = {
       "Stack" => %w[wing_pitch generic_component_height generic_top_gap
-                    gps_antenna_height gps_top_gap oled_component_height oled_face_gap],
+                    gps_antenna_height gps_top_gap oled_component_height
+                    oled_display_height oled_face_gap],
       "Shell and fit" => %w[wall_thickness floor_thickness lid_thickness corner_radius
-                            board_bottom_clearance board_side_clearance board_rear_clearance
+                            board_bottom_clearance board_side_clearance lid_lip_depth
-                            usb_board_wall_gap lid_lip_depth lid_lip_thickness fit_clearance
+                            lid_lip_thickness fit_clearance cutout_min_web hole_compensation
-                            hole_compensation lid_screw_head_diameter lid_screw_head_height],
+                            lid_screw_head_diameter lid_screw_head_height],
       "M2.5 inserts" => %w[m25_insert_length m25_insert_hole_diameter
                            m25_screw_clearance m25_boss_diameter
                            insert_entry_chamfer insert_melt_relief],
@@ -93,7 +101,8 @@ module FeatherCaseWizard
                                  switch_flange_diameter switch_body_length
                                  switch_body_diameter switch_wire_allowance],
       "USB-C opening" => %w[usb_opening_width usb_opening_height
-                            usb_opening_radius usb_vertical_offset],
+                            usb_opening_radius usb_vertical_offset usb_connector_overhang
+                            usb_guide_wall_thickness usb_guide_end_gap],
       "OLED buttons" => %w[button_projection button_flange_thickness
                            button_travel button_contact_extension]
     }.freeze
@@ -264,6 +273,9 @@ module FeatherCaseWizard
       unless (outputs["coupons"] - COUPONS).empty?
         raise ConfigError, "Unsupported calibration coupon"
       end
+      if parameters["usb_guide_enabled"] && !parameters["usb_opening_enabled"]
+        raise ConfigError, "USB guide requires the USB opening"
+      end
 
       positive = DEFAULT_PARAMETERS.keys - %w[usb_vertical_offset stack_height_override]
       positive.each do |key|
@@ -289,7 +301,10 @@ module FeatherCaseWizard
     def normalize!
       data["schema_version"] = Integer(data.fetch("schema_version", SCHEMA_VERSION))
       data["generator"] ||= {}
-      data["parameters"] = self.class.deep_copy(DEFAULT_PARAMETERS).merge(data["parameters"] || {})
+      supplied_parameters = data["parameters"] || {}
+      legacy_usb_guide = !supplied_parameters.key?("usb_guide_enabled")
+      data["parameters"] = self.class.deep_copy(DEFAULT_PARAMETERS).merge(supplied_parameters)
+      data["parameters"]["usb_guide_enabled"] = false if legacy_usb_guide
       data["cutouts"] ||= []
       data["outputs"] ||= {}
       data["outputs"]["formats"] ||= ["3mf"]
@@ -302,6 +317,7 @@ module FeatherCaseWizard
     def validate_cutouts!
       dims = dimensions
       names = {}
+      bounds = []
       cutouts.each do |cutout|
         name = cutout["name"].to_s.strip
         raise ConfigError, "Every cutout needs a name" if name.empty?
@@ -328,9 +344,68 @@ module FeatherCaseWizard
         radius = Float(cutout.fetch("radius", [width, height].min / 2))
         raise ConfigError, "#{name} dimensions must be positive" unless
           width.positive? && height.positive? && radius.positive?
+        bounds << {
+          "name" => name, "face" => face,
+          "left" => horizontal - width / 2, "right" => horizontal + width / 2,
+          "bottom" => z - height / 2, "top" => z + height / 2
+        }
       rescue ArgumentError, TypeError, KeyError => e
         raise ConfigError, "Invalid cutout #{name.inspect}: #{e.message}"
       end
+      validate_cutout_spacing!(bounds, dims)
+    end
+
+    def validate_cutout_spacing!(bounds, dims)
+      web = parameters["cutout_min_web"]
+      bounds.combination(2) do |first, second|
+        next unless first["face"] == second["face"]
+        next if bounds_separated?(first, second, web)
+
+        raise ConfigError,
+              "#{first["name"]} and #{second["name"]} are too close on the #{first["face"]} wall"
+      end
+      return unless parameters["usb_opening_enabled"]
+
+      usb = usb_wall_bounds(dims)
+      bounds.select { |item| item["face"] == "front" }.each do |cutout|
+        next if bounds_separated?(cutout, usb, web)
+
+        raise ConfigError, "#{cutout["name"]} is too close to the USB opening or guide"
+      end
+    end
+
+    def bounds_separated?(first, second, web)
+      first["right"] + web <= second["left"] ||
+        second["right"] + web <= first["left"] ||
+        first["top"] + web <= second["bottom"] ||
+        second["top"] + web <= first["bottom"]
+    end
+
+    def usb_wall_bounds(dims)
+      p = parameters
+      effective_floor = p["tripod_insert_enabled"] ?
+        [p["floor_thickness"], p["tripod_insert_length"] + p["insert_melt_relief"] + 1.2].max :
+        p["floor_thickness"]
+      effective_board_clearance = [
+        p["board_bottom_clearance"],
+        p["m25_insert_length"] + p["insert_melt_relief"] + 0.6
+      ].max
+      board_top_z = effective_floor + effective_board_clearance + 1.6
+      global_y = p["wall_thickness"] + p["board_side_clearance"] + 11.43
+      horizontal = dims["width"] - global_y
+      z = board_top_z + 1.6 + p["usb_vertical_offset"]
+      guide_length = [
+        p["usb_board_wall_gap"] - p["usb_connector_overhang"] - p["usb_guide_end_gap"], 0
+      ].max
+      guide_active = p["usb_guide_enabled"] && guide_length.positive?
+      shell = guide_active ? 2 * p["usb_guide_wall_thickness"] : 0
+      width = p["usb_opening_width"] + p["hole_compensation"] + shell
+      height = p["usb_opening_height"] + p["hole_compensation"] + shell
+      {
+        "name" => "USB opening", "face" => "front",
+        "left" => horizontal - width / 2, "right" => horizontal + width / 2,
+        "bottom" => z - height / 2, "top" => z + height / 2
+      }
     end
 
     def stringify_keys(value)

lib/feather_case_wizard/prompting_ui.rb

@@ -0,0 +1,46 @@
+# frozen_string_literal: true
+
+module FeatherCaseWizard
+  class PromptingUI
+    def self.wrap(ui)
+      ui.is_a?(self) ? ui : new(ui)
+    end
+
+    def initialize(ui)
+      @ui = ui
+    end
+
+    def ask(*arguments, &block)
+      separate_after { @ui.ask(*arguments, &block) }
+    end
+
+    def agree(*arguments, &block)
+      separate_after { @ui.agree(*arguments, &block) }
+    end
+
+    def choose(prompt, &block)
+      separate_after do
+        @ui.choose do |menu|
+          menu.header = prompt.to_s.sub(/[?:]\s*\z/, "")
+          block.call(menu)
+        end
+      end
+    end
+
+    def say(*arguments, &block)
+      @ui.say(*arguments, &block)
+    end
+
+    def color(*arguments, &block)
+      @ui.color(*arguments, &block)
+    end
+
+    private
+
+    def separate_after
+      result = yield
+      @ui.say("\n")
+      result
+    end
+  end
+end

lib/feather_case_wizard/wizard.rb

@@ -5,7 +5,7 @@ module FeatherCaseWizard
     attr_reader :ui
 
     def initialize(ui: HighLine.new)
-      @ui = ui
+      @ui = PromptingUI.wrap(ui)
     end
 
     def create
@@ -15,14 +15,14 @@ module FeatherCaseWizard
     end
 
     def edit(config)
-      ui.say("\nEditing #{config.name} (`#{config.slug}`)")
+      ui.say("Editing #{config.name} (`#{config.slug}`)")
       config.data["name"] = text("Case name", config.name)
       configure(config, new_case: false)
     end
 
     def confirm_build(config)
       dims = config.dimensions
-      ui.say("\n#{ui.color("Build summary", :bold)}")
+      ui.say(ui.color("Build summary", :bold))
       ui.say("  Case: #{config.name} (#{config.slug})")
       ui.say("  Profile: #{config.parameters["top_profile"]}")
       ui.say("  Wings: #{config.parameters["wing_count"]}")
@@ -42,6 +42,7 @@ module FeatherCaseWizard
       choose_formats(config)
       choose_profile(config)
       choose_stack(config)
+      choose_end_clearance(config)
       choose_features(config)
       manage_cutouts(config)
       choose_coupons(config)
@@ -63,7 +64,7 @@ module FeatherCaseWizard
         menu.choice("3MF") { ["3mf"] }
         menu.choice("STL") { ["stl"] }
         menu.choice("Both 3MF and STL") { %w[3mf stl] }
-        menu.default = label == "both" ? 3 : (label == "stl" ? 2 : 1)
+        menu.default = (label == "both" ? 3 : (label == "stl" ? 2 : 1)).to_s
       end
       config.outputs["formats"] = selected
     end
@@ -74,7 +75,7 @@ module FeatherCaseWizard
         menu.choice("Generic / other") { "generic" }
         menu.choice("GPS") { "gps" }
         menu.choice("128×64 OLED") { "oled128x64" }
-        menu.default = {"generic" => 1, "gps" => 2, "oled128x64" => 3}.fetch(current)
+        menu.default = {"generic" => 1, "gps" => 2, "oled128x64" => 3}.fetch(current).to_s
       end
     end
 
@@ -82,11 +83,11 @@ module FeatherCaseWizard
       p = config.parameters
       p["wing_count"] = integer("Number of FeatherWings", p["wing_count"], 1..8)
       measured = p["stack_height_override"].positive?
-      if ui.agree("Use a measured board-to-top-PCB stack height? (y/n) ") do |question|
+      if ui.agree("Use a measured Feather-PCB-top to top-Wing-PCB stack height? (y/n) ") do |question|
         question.default = measured ? "yes" : "no"
       end
         p["stack_height_override"] = number(
-          "Measured height in mm", measured ? p["stack_height_override"] :
+          "PCB-top to PCB-top height in mm", measured ? p["stack_height_override"] :
           p["wing_count"] * p["wing_pitch"], min: 0.1
         )
       else
@@ -96,22 +97,55 @@ module FeatherCaseWizard
 
     def choose_features(config)
       p = config.parameters
+      p["usb_opening_enabled"] = agreement(
+        "Include front USB-C programming opening?", p["usb_opening_enabled"]
+      )
+      p["usb_guide_enabled"] = if p["usb_opening_enabled"]
+                                 agreement("Include inward USB plug guide?",
+                                           p["usb_guide_enabled"])
+                               else
+                                 false
+                               end
       p["battery_enabled"] = agreement("Include 18650 battery compartment and switch?",
                                         p["battery_enabled"])
       p["tripod_insert_enabled"] = agreement("Include centered 1/4-20 insert?",
                                               p["tripod_insert_enabled"])
       return unless p["top_profile"] == "oled128x64"
 
-      ui.say("\nOLED captive buttons")
+      ui.say("OLED captive buttons")
       p["button_a"] = agreement("Enable button A?", p["button_a"])
       p["button_b"] = agreement("Enable button B?", p["button_b"])
       p["button_c"] = agreement("Enable button C?", p["button_c"])
       p["button_reset"] = agreement("Enable reset button?", p["button_reset"])
     end
 
+    def choose_end_clearance(config)
+      p = config.parameters
+      defaults = Config::DEFAULT_PARAMETERS
+      custom = p["usb_board_wall_gap"] != defaults["usb_board_wall_gap"] ||
+        p["board_rear_clearance"] != defaults["board_rear_clearance"]
+      enabled = ui.agree("Use extra clearance beyond the Feather PCB ends? (y/n) ") do |question|
+        question.default = custom ? "yes" : "no"
+      end
+      unless enabled
+        p["usb_board_wall_gap"] = defaults["usb_board_wall_gap"]
+        p["board_rear_clearance"] = defaults["board_rear_clearance"]
+        return
+      end
+
+      p["usb_board_wall_gap"] = number(
+        "USB/front PCB-edge to inner-wall clearance (mm)",
+        p["usb_board_wall_gap"], min: 0.1
+      )
+      p["board_rear_clearance"] = number(
+        "Rear PCB-edge to inner-wall clearance (mm)",
+        p["board_rear_clearance"], min: 0.1
+      )
+    end
+
     def manage_cutouts(config)
       loop do
-        ui.say("\nCustom cable cutouts: #{config.cutouts.empty? ? "none" :
+        ui.say("Custom cable cutouts: #{config.cutouts.empty? ? "none" :
           config.cutouts.map { |cutout| cutout["name"] }.join(", ")}")
         action = ui.choose("Cable cutouts") do |menu|
           menu.choice("Done") { :done }
@@ -141,12 +175,15 @@ module FeatherCaseWizard
       dims = config.dimensions
       name = text("Cutout name", existing["name"] || "cable")
       face = ui.choose("Wall") do |menu|
-        Config::FACES.each { |item| menu.choice(item) { item } }
+        menu.choice("Front — USB-C short wall") { "front" }
-        menu.default = Config::FACES.index(existing["face"]).to_i + 1 if existing["face"]
+        menu.choice("Rear — opposite short wall") { "rear" }
+        menu.choice("Left — plain/non-JST long wall") { "left" }
+        menu.choice("Right — JST/battery long wall") { "right" }
+        menu.default = (Config::FACES.index(existing["face"]).to_i + 1).to_s if existing["face"]
       end
       shape = ui.choose("Shape") do |menu|
         Config::SHAPES.each { |item| menu.choice(item) { item } }
-        menu.default = Config::SHAPES.index(existing["shape"]).to_i + 1 if existing["shape"]
+        menu.default = (Config::SHAPES.index(existing["shape"]).to_i + 1).to_s if existing["shape"]
       end
       wall_width = %w[front rear].include?(face) ? dims["width"] : dims["length"]
       ui.say("Viewing the #{face} wall from outside: width #{format("%.1f", wall_width)} mm; " \
@@ -209,7 +246,7 @@ module FeatherCaseWizard
       Config::ADVANCED_FIELDS.each do |section, fields|
         next unless ui.agree("Adjust #{section.downcase}? (y/n) ") { |q| q.default = "no" }
 
-        ui.say("\n#{section}")
+        ui.say(section)
         fields.each do |field|
           config.parameters[field] = number(field.tr("_", " "), config.parameters[field],
                                              min: field == "usb_vertical_offset" ? nil : 0.01)
@@ -286,4 +323,3 @@ module FeatherCaseWizard
     def yes_no(value) = value ? "yes" : "no"
   end
 end
-

test/cli_test.rb

@@ -0,0 +1,16 @@
+# frozen_string_literal: true
+
+require "stringio"
+require_relative "test_helper"
+
+class CLITest < Minitest::Test
+  def test_main_prompt_is_not_an_extra_choice
+    output = StringIO.new
+    cli = FeatherCaseWizard::CLI.new(ui: HighLine.new(StringIO.new("4\n"), output))
+
+    assert_equal 0, cli.run
+    assert_includes output.string, "What would you like to do:\n"
+    assert_includes output.string, "4. Exit\n"
+    refute_includes output.string, "5. What would you like to do?"
+  end
+end

test/config_test.rb

@@ -9,11 +9,77 @@ class ConfigTest < Minitest::Test
 
   def test_default_case_has_expected_parts_and_dimensions
     assert_equal %w[body lid], config.printable_parts
-    assert_in_delta 60.8, config.dimensions["length"], 0.01
+    assert_in_delta 61.6, config.dimensions["length"], 0.01
     assert_in_delta 41.66, config.dimensions["width"], 0.01
+    assert_in_delta 12.25, config.parameters["wing_pitch"], 0.001
+    assert_in_delta 6.0, config.parameters["gps_antenna_height"], 0.001
+    assert_in_delta 2.4, config.parameters["oled_component_height"], 0.001
+    assert_in_delta 1.5, config.parameters["oled_display_height"], 0.001
+    assert_in_delta 2.0, config.parameters["usb_board_wall_gap"], 0.001
+    assert config.parameters["usb_opening_enabled"]
+    assert config.parameters["usb_guide_enabled"]
     assert_equal ["3mf"], config.outputs["formats"]
   end
 
+  def test_gps_height_uses_stack_pitch_antenna_height_and_top_gap
+    subject = config
+    subject.parameters["top_profile"] = "gps"
+    parameters = subject.parameters
+
+    expected_electronics_height =
+      parameters["wing_pitch"] + parameters["gps_antenna_height"] +
+      parameters["gps_top_gap"]
+
+    assert_in_delta 23.25, expected_electronics_height, 0.001
+    assert_in_delta 35.85, subject.dimensions["height"] + parameters["lid_thickness"], 0.001
+  end
+
+  def test_oled_height_uses_tallest_component_not_display_reference
+    subject = config
+    subject.parameters["top_profile"] = "oled128x64"
+    original_height = subject.dimensions["height"]
+
+    subject.parameters["oled_display_height"] = 10.0
+
+    assert_in_delta original_height, subject.dimensions["height"], 0.001
+  end
+
+  def test_older_config_receives_default_oled_display_height
+    data = FeatherCaseWizard::Config.deep_copy(config.data)
+    data["parameters"].delete("oled_display_height")
+
+    loaded = FeatherCaseWizard::Config.new(data)
+
+    assert_in_delta 1.5, loaded.parameters["oled_display_height"], 0.001
+  end
+
+  def test_older_config_preserves_opening_without_enabling_guide
+    data = FeatherCaseWizard::Config.deep_copy(config.data)
+    data["parameters"].delete("usb_opening_enabled")
+    data["parameters"].delete("usb_guide_enabled")
+
+    loaded = FeatherCaseWizard::Config.new(data)
+
+    assert loaded.parameters["usb_opening_enabled"]
+    refute loaded.parameters["usb_guide_enabled"]
+  end
+
+  def test_usb_guide_requires_opening
+    subject = config
+    subject.parameters["usb_opening_enabled"] = false
+
+    error = assert_raises(FeatherCaseWizard::ConfigError) { subject.validate! }
+    assert_match(/guide requires/, error.message)
+  end
+
+  def test_end_clearances_expand_case_length
+    subject = config
+    subject.parameters["usb_board_wall_gap"] = 20.0
+    subject.parameters["board_rear_clearance"] = 20.0
+
+    assert_in_delta 95.6, subject.dimensions["length"], 0.01
+  end
+
   def test_oled_buttons_and_selected_coupons_are_printable
     subject = config
     subject.parameters["top_profile"] = "oled128x64"
@@ -50,6 +116,33 @@ class ConfigTest < Minitest::Test
     assert_match(/floor/, error.message)
   end
 
+  def test_cutouts_on_same_wall_require_minimum_web
+    subject = config
+    first = cutout("rear", 18.0).merge("name" => "first")
+    second = cutout("rear", 24.0).merge("name" => "second")
+    subject.data["cutouts"] = [first, second]
+
+    error = assert_raises(FeatherCaseWizard::ConfigError) { subject.validate! }
+    assert_match(/too close/, error.message)
+  end
+
+  def test_front_cutout_cannot_overlap_usb_opening
+    subject = config
+    subject.data["cutouts"] = [
+      cutout("front", subject.dimensions["width"] / 2).merge("z" => 11.0)
+    ]
+
+    error = assert_raises(FeatherCaseWizard::ConfigError) { subject.validate! }
+    assert_match(/USB opening or guide/, error.message)
+  end
+
+  def test_front_cutout_can_clear_usb_reservation
+    subject = config
+    subject.data["cutouts"] = [cutout("front", 10.0).merge("z" => 11.0)]
+
+    assert_same subject, subject.validate!
+  end
+
   def test_yaml_round_trip_preserves_resolved_cutouts
     subject = config
     subject.data["cutouts"] = [cutout("left", 20.0)]

test/prompting_ui_test.rb

@@ -0,0 +1,31 @@
+# frozen_string_literal: true
+
+require "stringio"
+require_relative "test_helper"
+
+class PromptingUITest < Minitest::Test
+  def test_menu_prompt_is_a_header_and_answers_are_separated
+    output = StringIO.new
+    ui = FeatherCaseWizard::PromptingUI.wrap(
+      HighLine.new(StringIO.new("1\nDemo\n"), output)
+    )
+
+    selected = ui.choose("Export format (current: 3mf)") do |menu|
+      menu.choice("3MF") { "3mf" }
+      menu.choice("STL") { "stl" }
+    end
+    name = ui.ask("Case name: ")
+
+    assert_equal "3mf", selected
+    assert_equal "Demo", name
+    assert_includes output.string, "Export format (current: 3mf):\n1. 3MF\n2. STL\n?  \n"
+    refute_includes output.string, "3. Export format"
+    assert_match(/\?  \nCase name: /, output.string)
+  end
+
+  def test_wrap_is_idempotent
+    ui = FeatherCaseWizard::PromptingUI.wrap(HighLine.new)
+
+    assert_same ui, FeatherCaseWizard::PromptingUI.wrap(ui)
+  end
+end

test/wizard_test.rb

@@ -6,20 +6,8 @@ require_relative "test_helper"
 class WizardTest < Minitest::Test
   def test_minimal_new_case_flow_and_confirmation
     input = StringIO.new(
-      "Demo Case\n" \
+      ["Demo Case", "", "1", "1", "", "n", "n", "", "", "n", "n", "1",
-      "\n" \
+       "n", "n", "n", "n", "y"].join("\n") + "\n"
-      "1\n" \
-      "1\n" \
-      "\n" \
-      "n\n" \
-      "n\n" \
-      "n\n" \
-      "1\n" \
-      "n\n" \
-      "n\n" \
-      "n\n" \
-      "n\n" \
-      "y\n"
     )
     output = StringIO.new
     wizard = FeatherCaseWizard::Wizard.new(ui: HighLine.new(input, output))
@@ -31,4 +19,55 @@ class WizardTest < Minitest::Test
     assert_equal ["3mf"], config.outputs["formats"]
     assert_equal %w[body lid], config.printable_parts
   end
+
+  def test_edit_accepts_current_menu_choices_as_defaults
+    config = FeatherCaseWizard::Config.create(name: "GPS", slug: "gps")
+    config.parameters["top_profile"] = "gps"
+    input = StringIO.new(
+      ["", "", "", "", "n", "n", "", "", "n", "n", "1", "n", "n", "n",
+       "n"].join("\n") + "\n"
+    )
+    wizard = FeatherCaseWizard::Wizard.new(ui: HighLine.new(input, StringIO.new))
+
+    edited = wizard.edit(config)
+
+    assert_equal ["3mf"], edited.outputs["formats"]
+    assert_equal "gps", edited.parameters["top_profile"]
+  end
+
+  def test_edit_cutout_accepts_current_wall_and_shape_as_defaults
+    config = FeatherCaseWizard::Config.create(name: "GPS", slug: "gps")
+    cutout = {
+      "name" => "cable",
+      "face" => "left",
+      "shape" => "roundrect",
+      "horizontal" => 30.0,
+      "z" => 12.0,
+      "width" => 8.0,
+      "height" => 6.0,
+      "radius" => 1.5
+    }
+    output = StringIO.new
+    wizard = FeatherCaseWizard::Wizard.new(ui: HighLine.new(StringIO.new("\n" * 8), output))
+
+    edited = wizard.send(:ask_cutout, config, cutout)
+
+    assert_equal "left", edited["face"]
+    assert_equal "roundrect", edited["shape"]
+    assert_includes output.string, "Wall:\n1. Front — USB-C short wall\n"
+    assert_includes output.string, "3. Left — plain/non-JST long wall\n"
+    refute_includes output.string, "5. Wall"
+  end
+
+  def test_end_clearance_step_sets_both_board_end_distances
+    config = FeatherCaseWizard::Config.create(name: "Servo", slug: "servo")
+    wizard = FeatherCaseWizard::Wizard.new(
+      ui: HighLine.new(StringIO.new("y\n20\n20\n"), StringIO.new)
+    )
+
+    wizard.send(:choose_end_clearance, config)
+
+    assert_in_delta 20.0, config.parameters["usb_board_wall_gap"], 0.001
+    assert_in_delta 20.0, config.parameters["board_rear_clearance"], 0.001
+  end
 end