tweak the fit of the parts

This commit is contained in:
Nick Estes
2026-08-04 12:27:31 -07:00
parent 45a77885f9
commit 69d9b956e6
41 changed files with 5378 additions and 324 deletions
+38 -14
View File
@@ -28,15 +28,15 @@ print, or rebuild an existing case. Generated definitions live under
`cases/<name>/`; exports, previews, revision history, and `vendor/bundle` are
ignored by Git.
OpenSCAD and Blender must be available on `PATH`. On Ubuntu:
OpenSCAD, Blender, and Python 3 must be available on `PATH`. On Ubuntu:
```bash
sudo apt-get install openscad blender
sudo apt-get install openscad blender python3
```
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.
Set `OPENSCAD=/path/to/openscad`, `BLENDER=/path/to/blender`, or
`PYTHON=/path/to/python3` when a program is installed elsewhere. The wizard
checks all three 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
@@ -132,6 +132,25 @@ 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.
When the battery compartment and tripod insert are both enabled, the generator
adds board-side clearance to keep the insert centered across the case width and
moves it 5 mm toward the USB wall to clear the nearest Feather standoff. The
battery partition defaults to three 0.6 mm extrusion lines and can be adjusted
with `battery_partition_thickness`.
## Two-color lid artwork
Set `lid_label` to a device name and/or enable `lid_logo_enabled` to add flush
second-color artwork to non-OLED lids. Choose `lid_art_orientation` from
`usb_left`, `usb_front`, `usb_right`, or `usb_rear`; it describes where the USB
edge sits when the exterior artwork is upright. OLED profiles reject lid
artwork until a window/button-safe layout is defined.
Generated artwork packages include separate `lid_base` and `lid_accent` meshes,
a complete single-color `lid`, and `lid_multicolor.3mf`. The multicolor file is
one aligned multipart object with its base assigned to filament 1 and its logo
and title assigned to filament 2. Print the lid exterior-face-down.
## Custom wire egress
`extra_cutouts` accepts any number of entries:
@@ -164,9 +183,11 @@ points.
1. Export and print `part="insert_coupon"` in the intended material.
2. Test both M2.5 and 1/4-20 inserts in the five stepped holes.
3. Set `m25_insert_hole_diameter` and `tripod_insert_hole_diameter` to the best
coupon values.
4. Print `part="switch_coupon"` and choose the best hole for the actual DMWD
switch batch.
coupon values. These parameters are the finished pilot diameters in the
model; `hole_compensation` is not added to heat-set pockets. The coupon uses
the same tapered pocket geometry as the cases.
4. Print `part="switch_coupon"` and choose the best rounded-rectangle opening
for the actual KCD1-101 rocker-switch batch.
5. Print `part="fit_coupon"` and tune `fit_clearance` before committing to the
complete lid and body.
@@ -180,13 +201,16 @@ temperature control, and the same extrusion settings intended for the case.
opening faces the exterior bottom.
2. Heat-set four M2.5 inserts into the board standoffs.
3. Fasten the ESP32 Feather V2, then install the stacking headers and Wings.
4. For battery builds, place the protected 69 x 18 mm pack in the cradle, route
its lead through the partition notch, and mount the latching switch in the
battery-side wall.
5. Heat-set the four lid inserts downward into the corner bosses.
6. For OLED builds, insert each enabled printed plunger through the lid from
4. For battery builds, place the protected 69 x 18 mm pack in the cradle and
route its lead through the combined front partition/JST opening and beneath
the Feather PCB.
5. Snap the KCD1-101 rocker switch into the rear lid opening, connect its bent
quick-connect terminals or low-profile wiring, and lower the wired lid onto
the case.
6. Heat-set the four lid inserts downward into the corner bosses.
7. For OLED builds, insert each enabled printed plunger through the lid from
the inside. The elongated flange stays in the internal recess.
7. Engage the lid rim and fasten four standard M2.5 socket-head screws into the
8. Engage the lid rim and fasten four standard M2.5 socket-head screws into the
2.5 mm-deep counterbores.
Confirm the USB plug, switch, battery, insert, and lid fits without force before