Initial parametric Feather case generator
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Nick Estes
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# Parametric Feather Case
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An OpenSCAD enclosure generator for the Adafruit ESP32 Feather V2, stacked
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FeatherWings, an optional protected 18650 pack, and an optional 1/4-20 camera
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mount. It produces a body, removable lid, OLED button plungers, and fit
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calibration coupons.
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## Interactive Ruby wizard
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The HighLine wizard asks the project-specific questions, saves the answers in
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YAML, and builds a self-contained case directory with OpenSCAD source, STL
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and/or 3MF geometry, and rendered previews.
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Install the Ruby dependency into this repository:
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```bash
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bundle install
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```
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Then run:
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```bash
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bundle exec bin/feather-case
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```
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The menu can create a case, reopen one for dimensional tuning after a test
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print, or rebuild an existing case. Generated definitions live under
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`cases/<name>/`; exports, previews, revision history, and `vendor/bundle` are
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ignored by Git.
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OpenSCAD and Blender must be available on `PATH`. On Ubuntu:
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```bash
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sudo apt-get install openscad blender
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```
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Set `OPENSCAD=/path/to/openscad` or `BLENDER=/path/to/blender` when either
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program is installed elsewhere. The wizard checks both tools before replacing
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an existing package.
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Each generated directory contains a dependency-free `build.rb`. After copying
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that directory to another Ubuntu machine, run `ruby build.rb` to reproduce its
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exports and previews. The saved generator source is used by default so a
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fine-tuning pass cannot silently pick up later geometry changes.
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OpenSCAD's 3MF output contains portable model geometry. It does not contain a
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Bambu printer, filament, plate, or process profile; select those settings after
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opening the files in Bambu Studio.
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The design targets support-free FDM printing with a 0.6 mm nozzle. PLA and PETG
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are suitable for general use; ASA is the preferred starting material for
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outdoor exposure. The enclosure is not weather-sealed.
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## Reference geometry
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All dimensions are millimetres. Board coordinates come from Adafruit's source
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files:
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- [ESP32 Feather V2 PCB](https://github.com/adafruit/Adafruit-ESP32-Feather-V2-PCB)
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- [ESP32 Feather V2 CAD](https://github.com/adafruit/Adafruit_CAD_Parts/tree/main/5400%20ESP32%20Feather%20V2)
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- [128x64 OLED FeatherWing PCB](https://github.com/adafruit/Adafruit-OLED-FeatherWing-PCB)
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- [128x64 OLED FeatherWing CAD](https://github.com/adafruit/Adafruit_CAD_Parts/tree/main/4650%20OLED%20FeatherWing)
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- [Adafruit 69 x 18 mm protected 18650 pack](https://www.adafruit.com/product/1781)
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The board origin is its USB edge at `(0, 0)`. The case uses X from the USB wall
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toward the rear, Y from the plain side toward the battery/JST side, and Z up
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from the exterior bottom.
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## Generate parts
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Open [feather_case.scad](feather_case.scad) in OpenSCAD and use the Customizer,
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or override values from the command line:
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```bash
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# Generic one-Wing case
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openscad -o body.stl -D 'part="body"' feather_case.scad
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openscad -o lid.stl -D 'part="lid"' feather_case.scad
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# Three-Wing GPS case with battery and camera mount
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openscad -o gps-body.stl \
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-D 'part="body"' \
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-D 'top_profile="gps"' \
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-D 'wing_count=3' \
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-D 'battery_enabled=true' \
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-D 'tripod_insert_enabled=true' \
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feather_case.scad
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openscad -o gps-lid.stl \
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-D 'part="lid"' \
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-D 'top_profile="gps"' \
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-D 'wing_count=3' \
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-D 'battery_enabled=true' \
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-D 'tripod_insert_enabled=true' \
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feather_case.scad
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# 128x64 OLED lid and all four captive buttons
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openscad -o oled-lid.stl \
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-D 'part="lid"' \
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-D 'top_profile="oled128x64"' \
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-D 'button_reset=true' \
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feather_case.scad
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openscad -o oled-buttons.stl \
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-D 'part="buttons"' \
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-D 'top_profile="oled128x64"' \
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-D 'button_reset=true' \
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feather_case.scad
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```
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The standard stack height is `wing_count * wing_pitch`. Set
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`stack_height_override` to the measured distance from the Feather PCB top to
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the top FeatherWing PCB when using unusual headers. It takes precedence over
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the computed height.
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## Custom wire egress
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`extra_cutouts` accepts any number of entries:
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```openscad
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// [face, shape, u, z, width, height, radius]
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extra_cutouts = [
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["left", "circle", 35, 10, 8, 8, 4],
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["rear", "roundrect", 20, 12, 14, 7, 2],
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["right", "slot", 28, 15, 18, 5, 2.5]
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];
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```
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Faces are `front`, `rear`, `left`, and `right`. For front/rear faces, `u` is
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the global Y coordinate; for left/right faces it is global X. The Z value is
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the opening centre. Shapes are `circle`, `rect`, `roundrect`, and `slot`.
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Cutouts that enter the floor or lid-lip keepout raise an assertion instead of
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silently weakening those features.
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## Calibration
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Heat-set insert holes vary significantly by insert brand, filament, nozzle,
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temperature, and printer calibration. Treat the supplied values as starting
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points.
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1. Export and print `part="insert_coupon"` in the intended material.
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2. Test both M2.5 and 1/4-20 inserts in the five stepped holes.
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3. Set `m25_insert_hole_diameter` and `tripod_insert_hole_diameter` to the best
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coupon values.
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4. Print `part="switch_coupon"` and choose the best hole for the actual DMWD
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switch batch.
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5. Print `part="fit_coupon"` and tune `fit_clearance` before committing to the
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complete lid and body.
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For ASA, tune dimensional compensation with coupons rather than applying an
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assumed global shrink percentage. Start with four or more walls, good chamber
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temperature control, and the same extrusion settings intended for the case.
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## Assembly
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1. Heat-set the optional 1/4-20 insert from inside the case. Its threaded
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opening faces the exterior bottom.
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2. Heat-set four M2.5 inserts into the board standoffs.
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3. Fasten the ESP32 Feather V2, then install the stacking headers and Wings.
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4. For battery builds, place the protected 69 x 18 mm pack in the cradle, route
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its lead through the partition notch, and mount the latching switch in the
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battery-side wall.
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5. Heat-set the four lid inserts downward into the corner bosses.
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6. For OLED builds, insert each enabled printed plunger through the lid from
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the inside. The elongated flange stays in the internal recess.
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7. Engage the lid rim and fasten four standard M2.5 socket-head screws into the
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2.5 mm-deep counterbores.
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Confirm the USB plug, switch, battery, insert, and lid fits without force before
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leaving a lithium-ion battery installed. The battery cradle is intended for
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Adafruit's protected pack, not an unprotected loose cell.
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