case updates

README.md

@@ -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
+Set `OPENSCAD=/path/to/openscad`, `BLENDER=/path/to/blender`, or
-program is installed elsewhere. The wizard checks both tools before replacing
+`PYTHON=/path/to/python3` when a program is installed elsewhere. The wizard
-an existing package.
+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.
+   coupon values. These parameters are the finished pilot diameters in the
-4. Print `part="switch_coupon"` and choose the best hole for the actual DMWD
+   model; `hole_compensation` is not added to heat-set pockets. The coupon uses
-   switch batch.
+   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
+4. For battery builds, place the protected 69 x 18 mm pack in the cradle and
-   its lead through the partition notch, and mount the latching switch in the
+   route its lead through the combined front partition/JST opening and beneath
-   battery-side wall.
+   the Feather PCB.
-5. Heat-set the four lid inserts downward into the corner bosses.
+5. Snap the KCD1-101 rocker switch into the rear lid opening, connect its bent
-6. For OLED builds, insert each enabled printed plunger through the lid from
+   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

assets/NME-fixed.svg

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cases/attitude-imu/README.md

@@ -1,25 +0,0 @@
-# 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/parameters.json

@@ -1,69 +0,0 @@
-{
-  "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

@@ -1,872 +0,0 @@
-/*
- * 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-no-battery/README.md

@@ -0,0 +1,31 @@
+# Attitude no battery
+
+Generated by the Feather Case Wizard.
+
+- Top profile: `generic`
+- FeatherWings: 1
+- Battery compartment: no
+- 1/4-20 insert: yes
+- Approximate exterior: 61.6 × 41.7 × 34.4 mm
+- Formats: 3mf
+- Parts: `body`, `lid`, `lid_base`, `lid_accent`
+- Custom cutouts: 0
+
+Run `ruby build.rb` in this directory to regenerate exports and previews.
+OpenSCAD, Blender, and Python 3 must be installed. Set `OPENSCAD`,
+`BLENDER`, or `PYTHON` to override their executable paths.
+
+To open the saved Customizer values manually:
+
+```bash
+openscad -p parameters.json -P attitude-no-battery source/feather_case.scad
+```
+
+The 3MF files contain portable geometry only. Choose printer, filament,
+plate, and slicing settings in Bambu Studio.
+
+For a two-color lid, open `exports/3mf/lid_multicolor.3mf` as one
+multipart object. Assign “Lid base — Filament 1” and “Accent inlays —
+Filament 2” to the desired filaments. `lid.3mf` is the complete
+single-color fallback; `lid_base.3mf` and `lid_accent.3mf` are also
+provided separately.

cases/attitude-no-battery/build.rb

@@ -44,13 +44,18 @@ config = YAML.safe_load_file(ROOT.join("case.yml"), permitted_classes: [],
                              permitted_symbols: [], aliases: false)
 openscad = executable("OPENSCAD", "openscad")
 blender = executable("BLENDER", "blender")
+python = executable("PYTHON", "python3")
 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")
 )
+artwork = !parameters.fetch("lid_label", "").empty? ||
+          parameters.fetch("lid_logo_enabled", false)
+abort "Python 3 not found; install it or set PYTHON" if artwork && !python
 parts = %w[body lid] + config.fetch("outputs").fetch("coupons")
+parts.concat(%w[lid_base lid_accent]) if artwork
 buttons = %w[button_a button_b button_c button_reset]
 if parameters["top_profile"] == "oled128x64" &&
    buttons.any? { |name| parameters[name] }
@@ -80,6 +85,16 @@ begin
       puts "Exporting #{part}.#{format}…"
       export.call(directory.join("#{part}.#{format}"), part)
     end
+    if artwork && format == "3mf"
+      puts "Packaging lid_multicolor.3mf…"
+      run!(
+        python, ROOT.join("tools/package_multimaterial_3mf.py").to_s,
+        directory.join("lid_base.3mf").to_s,
+        directory.join("lid_accent.3mf").to_s,
+        directory.join("lid_multicolor.3mf").to_s,
+        "--title", "#{config.fetch("name")} Lid"
+      )
+    end
   end
 
   assembly = scratch.join("assembly.stl")
@@ -97,6 +112,16 @@ begin
     run!(blender, "--background", "-noaudio", "--python", renderer.to_s, "--",
          mesh.to_s, previews.to_s, part, "iso", env: render_env)
   end
+  if artwork
+    puts "Rendering multicolor lid preview…"
+    run!(
+      blender, "--background", "-noaudio", "--python",
+      ROOT.join("source/render_multicolor_lid.py").to_s, "--",
+      scratch.join("lid_base.stl").to_s,
+      scratch.join("lid_accent.stl").to_s,
+      previews.to_s, "lid_multicolor", parameters["lid_art_orientation"], env: render_env
+    )
+  end
 
   backup = ROOT.join(".build-old-#{Process.pid}")
   FileUtils.mkdir_p(backup)

cases/attitude-no-battery/case.yml

@@ -1,9 +1,9 @@
 ---
 schema_version: 1
-name: Attitude IMU
+name: Attitude no battery
-slug: attitude-imu
+slug: attitude-no-battery
 generator:
-  sha256: be611e3255e7d802719ebb0628e3d11481f8de05fc96c24d452f026d7b8e3353
+  sha256: 281917098487eeacd19a136ba27752698712e90cb4c03c6525a1ea3167c9ea13
   created_with: feather-case-wizard
 parameters:
   top_profile: generic
@@ -36,20 +36,30 @@ parameters:
   battery_diameter: 18.0
   battery_radial_clearance: 0.6
   battery_end_clearance: 1.0
-  switch_hole_diameter: 12.0
+  battery_partition_thickness: 1.8
-  switch_hole_compensation: 0.3
+  battery_board_clearance: 3.0
-  switch_cap_diameter: 8.0
+  rocker_cutout_size:
-  switch_flange_diameter: 16.2
+  - 12.9
-  switch_body_length: 24.0
+  - 19.4
-  switch_body_diameter: 12.0
+  rocker_corner_radius: 0.8
-  switch_wire_allowance: 3.0
+  rocker_body_size:
+  - 15.0
+  - 21.0
+  - 21.0
+  rocker_artwork_gap: 2.0
+  rocker_partition_offset: 2.0
+  rocker_tab_panel_thickness: 2.0
+  rocker_tab_land: 2.0
+  rocker_tab_taper_length: 0.6
   tripod_insert_enabled: true
-  tripod_insert_length: 6.4
+  tripod_insert_length: 5.0
-  tripod_insert_hole_diameter: 8.8
+  tripod_insert_hole_diameter: 7.2
+  tripod_insert_outer_diameter: 8.0
   tripod_thread_clearance_diameter: 6.8
   tripod_boss_diameter: 14.0
   m25_insert_length: 4.0
-  m25_insert_hole_diameter: 3.7
+  m25_insert_hole_diameter: 3.1
+  m25_insert_outer_diameter: 3.5
   m25_screw_clearance: 2.8
   m25_boss_diameter: 7.0
   insert_entry_chamfer: 0.6
@@ -61,17 +71,31 @@ parameters:
   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_width: 12.5
+  usb_opening_enabled: true
-  usb_opening_height: 7.0
+  usb_guide_enabled: true
+  usb_connector_overhang: 2.0
+  usb_guide_wall_thickness: 1.2
+  usb_guide_end_gap: 1.0
+  lid_label: IMU
+  lid_logo_enabled: true
+  lid_art_orientation: usb_front
+  lid_inlay_depth: 0.6
+  lid_inlay_fit_clearance: 0.08
+  lid_label_size: 5.0
+  lid_label_logo_gap: 2.0
+  lid_art_margin: 8.5
+  usb_opening_width: 13.5
+  usb_opening_height: 8.0
   usb_opening_radius: 1.5
-  usb_vertical_offset: 0.0
+  usb_vertical_offset: 0.5
 cutouts: []
 outputs:
   formats:

cases/attitude-no-battery/parameters.json

@@ -1,10 +1,10 @@
 {
   "parameterSets": {
-    "pan-tilt-head": {
+    "attitude-no-battery": {
-      "top_profile": "\"oled128x64\"",
+      "top_profile": "\"generic\"",
-      "wing_count": "3",
+      "wing_count": "1",
       "wing_pitch": "12.25",
-      "stack_height_override": "38.0",
+      "stack_height_override": "0.0",
       "generic_component_height": "3.0",
       "generic_top_gap": "2.0",
       "gps_antenna_height": "6.0",
@@ -27,20 +27,25 @@
       "battery_diameter": "18.0",
       "battery_radial_clearance": "0.6",
       "battery_end_clearance": "1.0",
-      "switch_hole_diameter": "12.0",
+      "battery_partition_thickness": "1.8",
-      "switch_hole_compensation": "0.3",
+      "battery_board_clearance": "3.0",
-      "switch_cap_diameter": "8.0",
+      "rocker_cutout_size": "[12.9,19.4]",
-      "switch_flange_diameter": "16.2",
+      "rocker_corner_radius": "0.8",
-      "switch_body_length": "24.0",
+      "rocker_body_size": "[15.0,21.0,21.0]",
-      "switch_body_diameter": "12.0",
+      "rocker_artwork_gap": "2.0",
-      "switch_wire_allowance": "3.0",
+      "rocker_partition_offset": "2.0",
+      "rocker_tab_panel_thickness": "2.0",
+      "rocker_tab_land": "2.0",
+      "rocker_tab_taper_length": "0.6",
       "tripod_insert_enabled": "true",
-      "tripod_insert_length": "6.4",
+      "tripod_insert_length": "5.0",
-      "tripod_insert_hole_diameter": "8.8",
+      "tripod_insert_hole_diameter": "7.2",
+      "tripod_insert_outer_diameter": "8.0",
       "tripod_thread_clearance_diameter": "6.8",
       "tripod_boss_diameter": "14.0",
       "m25_insert_length": "4.0",
-      "m25_insert_hole_diameter": "3.7",
+      "m25_insert_hole_diameter": "3.1",
+      "m25_insert_outer_diameter": "3.5",
       "m25_screw_clearance": "2.8",
       "m25_boss_diameter": "7.0",
       "insert_entry_chamfer": "0.6",
@@ -51,8 +56,8 @@
       "corner_radius": "4.0",
       "board_bottom_clearance": "5.4",
       "board_side_clearance": "7.0",
-      "board_rear_clearance": "20.0",
+      "board_rear_clearance": "4.0",
-      "usb_board_wall_gap": "20.0",
+      "usb_board_wall_gap": "2.0",
       "lid_lip_depth": "2.4",
       "lid_lip_thickness": "1.2",
       "fit_clearance": "0.35",
@@ -65,10 +70,18 @@
       "usb_connector_overhang": "2.0",
       "usb_guide_wall_thickness": "1.2",
       "usb_guide_end_gap": "1.0",
-      "usb_opening_width": "12.5",
+      "lid_label": "\"IMU\"",
-      "usb_opening_height": "7.0",
+      "lid_logo_enabled": "true",
+      "lid_art_orientation": "\"usb_front\"",
+      "lid_inlay_depth": "0.6",
+      "lid_inlay_fit_clearance": "0.08",
+      "lid_label_size": "5.0",
+      "lid_label_logo_gap": "2.0",
+      "lid_art_margin": "8.5",
+      "usb_opening_width": "13.5",
+      "usb_opening_height": "8.0",
       "usb_opening_radius": "1.5",
-      "usb_vertical_offset": "0.0"
+      "usb_vertical_offset": "0.5"
     }
   },
   "fileFormatVersion": "1"

cases/attitude-no-battery/source/assets/NME-fixed.svg

@@ -0,0 +1,82 @@
+<?xml version="1.0" encoding="UTF-8" standalone="no"?>
+<!-- Created with Inkscape (http://www.inkscape.org/) -->
+
+<svg
+   width="210mm"
+   height="297mm"
+   viewBox="0 0 210 297"
+   version="1.1"
+   id="svg584"
+   inkscape:version="1.2.2 (b0a8486541, 2022-12-01)"
+   sodipodi:docname="NME-fixed.svg"
+   xmlns:inkscape="http://www.inkscape.org/namespaces/inkscape"
+   xmlns:sodipodi="http://sodipodi.sourceforge.net/DTD/sodipodi-0.dtd"
+   xmlns="http://www.w3.org/2000/svg"
+   xmlns:svg="http://www.w3.org/2000/svg">
+  <sodipodi:namedview
+     id="namedview586"
+     pagecolor="#ffffff"
+     bordercolor="#666666"
+     borderopacity="1.0"
+     inkscape:showpageshadow="2"
+     inkscape:pageopacity="0.0"
+     inkscape:pagecheckerboard="0"
+     inkscape:deskcolor="#d1d1d1"
+     inkscape:document-units="mm"
+     showgrid="false"
+     inkscape:zoom="0.914906"
+     inkscape:cx="1166.24"
+     inkscape:cy="477.6447"
+     inkscape:window-width="3440"
+     inkscape:window-height="1390"
+     inkscape:window-x="0"
+     inkscape:window-y="1080"
+     inkscape:window-maximized="1"
+     inkscape:current-layer="layer1" />
+  <defs
+     id="defs581" />
+  <g
+     inkscape:label="Layer 1"
+     inkscape:groupmode="layer"
+     id="layer1">
+    <g
+       id="g772">
+      <path
+         id="path2"
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+         id="path6"
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+         id="path7"
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+           d="m 134.23594,367.14576 v 34.66667 h 69.06667 c 37.86666,0 71.06666,-0.4 73.86666,-0.8 4.4,-0.8 7.2,-3.73333 31.33333,-32.8 14.53334,-17.46667 26.53334,-32.4 26.8,-32.93333 0.26667,-0.66667 -0.93333,-1.46667 -2.66666,-2 -1.73334,-0.4 -47.06667,-0.8 -100.66667,-0.8 h -97.73333 z"
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+      </g>
+    </g>
+  </g>
+</svg>

cases/attitude-no-battery/source/feather_case.scad

@@ -12,7 +12,7 @@
  */
 
 /* [Output] */
-part = "assembly"; // [assembly,body,lid,buttons,insert_coupon,switch_coupon,fit_coupon]
+part = "assembly"; // [assembly,body,lid,lid_base,lid_accent,buttons,insert_coupon,switch_coupon,fit_coupon]
 exploded_view = 8; // [0:1:20]
 show_references = true;
 
@@ -47,24 +47,29 @@ battery_length = 69;
 battery_diameter = 18;
 battery_radial_clearance = 0.6;
 battery_end_clearance = 1;
-switch_hole_diameter = 12;
+battery_partition_thickness = 1.8;
-switch_hole_compensation = 0.3;
+battery_board_clearance = 3;
-switch_cap_diameter = 8;
+rocker_cutout_size = [12.9, 19.4];
-switch_flange_diameter = 16.2;
+rocker_corner_radius = 0.8;
-switch_body_length = 24;
+rocker_body_size = [15, 21, 21];
-switch_body_diameter = 12;
+rocker_artwork_gap = 2;
-switch_wire_allowance = 3;
+rocker_partition_offset = 2;
+rocker_tab_panel_thickness = 2;
+rocker_tab_land = 2;
+rocker_tab_taper_length = 0.6;
 
 /* [Tripod mount] */
 tripod_insert_enabled = false;
-tripod_insert_length = 6.4;
+tripod_insert_length = 5;
-tripod_insert_hole_diameter = 8.8;
+tripod_insert_hole_diameter = 7.2;
+tripod_insert_outer_diameter = 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_insert_hole_diameter = 3.1;
+m25_insert_outer_diameter = 3.5;
 m25_screw_clearance = 2.8;
 m25_boss_diameter = 7;
 insert_entry_chamfer = 0.6;
@@ -87,16 +92,27 @@ hole_compensation = 0.2;
 lid_screw_head_diameter = 5.2;
 lid_screw_head_height = 2.5;
 
+/* [Two-color lid artwork] */
+lid_label = "";
+lid_logo_enabled = false;
+lid_art_orientation = "usb_left"; // [usb_left,usb_front,usb_right,usb_rear]
+lid_inlay_depth = 0.6; // [0.4:0.2:1]
+lid_inlay_fit_clearance = 0.08;
+lid_label_size = 5;
+lid_label_logo_gap = 2;
+lid_art_margin = 8.5;
+logo_file = "assets/NME-fixed.svg";
+
 /* [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_width = 13.5;
-usb_opening_height = 7;
+usb_opening_height = 8;
 usb_opening_radius = 1.5;
-usb_vertical_offset = 0;
+usb_vertical_offset = 0.5;
 
 /* [Custom wall cutouts] */
 // Entry format: [face, shape, u, z, width, height, radius]
@@ -106,6 +122,8 @@ extra_cutouts = [];
 
 /* [Calibration] */
 coupon_steps = [-0.3, -0.15, 0, 0.15, 0.3];
+m25_coupon_steps = [-0.15, -0.075, 0, 0.075, 0.15];
+tripod_coupon_steps = [-0.3, -0.15, 0, 0.15, 0.3];
 
 $fn = $preview ? 36 : 72;
 eps = 0.02;
@@ -117,6 +135,9 @@ board_thickness = 1.6;
 mount_x = [2.54, 48.26];
 mount_y = [2.54, 20.32];
 usb_center_y = 11.43;
+jst_center_xy = [10.9855, 19.304];
+jst_body_size = [8, 7.5, 4.5];
+jst_relief_clearance = 0.5;
 
 // Official 128x64 OLED FeatherWing geometry in Feather-board coordinates.
 oled_visible_min = [11.42, 3.78];
@@ -133,9 +154,18 @@ effective_board_clearance = max(
     board_bottom_clearance,
     m25_insert_length + insert_melt_relief + 0.6
 );
+lid_boss_r = m25_boss_diameter / 2;
+lid_boss_wall_overlap = 0.6;
+front_lid_boss_center = wall_thickness + lid_boss_r
+    - lid_boss_wall_overlap;
+
+// Combined battery/tripod builds need room around the centered insert entry.
+combined_tripod_board_gutter = battery_enabled && tripod_insert_enabled ? 2.4 : 0;
+combined_tripod_x_shift = battery_enabled && tripod_insert_enabled ? 5 : 0;
 
 board_origin_x = wall_thickness + usb_board_wall_gap;
-board_origin_y = wall_thickness + board_side_clearance;
+board_origin_y = wall_thickness + board_side_clearance
+    + combined_tripod_board_gutter;
 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;
@@ -166,20 +196,17 @@ profile_top_gap =
     top_profile == "oled128x64" ? oled_face_gap :
     generic_top_gap;
 
-partition_y = board_origin_y + feather_width + 1;
+partition_y = board_origin_y + feather_width + battery_board_clearance;
-battery_center_y = partition_y + wall_thickness + battery_radial_clearance
+battery_center_y = partition_y + battery_partition_thickness
-    + battery_diameter / 2;
+    + battery_radial_clearance + battery_diameter / 2;
-battery_start_x = board_origin_x + battery_end_clearance;
+battery_start_x = front_lid_boss_center + lid_boss_r
+    + 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
+case_length_battery = battery_end_x + battery_end_clearance
-    + 1.2 + wall_thickness;
+    + wall_thickness + m25_boss_diameter - lid_boss_wall_overlap;
 case_length = battery_enabled ? max(case_length_plain, case_length_battery)
     : case_length_plain;
 
@@ -190,23 +217,74 @@ case_width_battery = battery_center_y + battery_diameter / 2
 case_width = battery_enabled ? max(case_width_plain, case_width_battery)
     : case_width_plain;
 
+rocker_installed_center_x = case_length - wall_thickness - fit_clearance
+    - lid_lip_thickness - fit_clearance - rocker_body_size[0] / 2;
+rocker_installed_center_y = front_lid_boss_center + lid_boss_r + fit_clearance
+    + rocker_body_size[1] / 2 + rocker_partition_offset;
+// The printable lid is flipped across Y when installed, so its local cutout
+// coordinate must be mirrored from the assembled switch location.
+rocker_lid_center_x = rocker_installed_center_x;
+rocker_lid_center_y = case_width - rocker_installed_center_y;
+
+lid_artwork_enabled = lid_label != "" || lid_logo_enabled;
+lid_art_rotation =
+    lid_art_orientation == "usb_left" ? 0 :
+    lid_art_orientation == "usb_front" ? 90 :
+    lid_art_orientation == "usb_right" ? 180 : 270;
+lid_art_safe_max_x = battery_enabled
+    ? rocker_lid_center_x - rocker_cutout_size[0] / 2 - rocker_artwork_gap
+    : case_length - lid_art_margin;
+lid_art_physical_size = [
+    lid_art_safe_max_x - lid_art_margin,
+    case_width - 2 * lid_art_margin
+];
+lid_art_center = [
+    lid_art_margin + lid_art_physical_size[0] / 2,
+    case_width / 2
+];
+lid_art_canvas_size = lid_art_rotation == 0 || lid_art_rotation == 180
+    ? lid_art_physical_size
+    : [lid_art_physical_size[1], lid_art_physical_size[0]];
+lid_art_available_size = lid_art_canvas_size;
+lid_label_height = lid_label == "" ? 0 : lid_label_size;
+lid_art_gap = lid_label != "" && lid_logo_enabled ? lid_label_logo_gap : 0;
+logo_native_size = [30, 25.75];
+logo_max_height = lid_art_available_size[1] - lid_label_height - lid_art_gap;
+logo_scale = lid_logo_enabled ? min(
+    lid_art_available_size[0] / logo_native_size[0],
+    logo_max_height / logo_native_size[1]
+) : 0;
+logo_size = [logo_native_size[0] * logo_scale,
+    logo_native_size[1] * logo_scale];
+lid_art_total_height = logo_size[1] + lid_art_gap + lid_label_height;
+lid_label_center_y = -lid_art_total_height / 2 + lid_label_height / 2;
+lid_logo_center_y = -lid_art_total_height / 2 + lid_label_height
+    + lid_art_gap + logo_size[1] / 2;
+
+tripod_center_x = case_length / 2 - combined_tripod_x_shift;
+tripod_center_y = case_width / 2;
+tripod_entry_radius = tripod_insert_outer_diameter / 2;
+tripod_standoff_clearance = min([
+    for (mx = mount_x, my = mount_y)
+        sqrt(
+            pow(board_origin_x + mx - tripod_center_x, 2)
+            + pow(board_origin_y + my - tripod_center_y, 2)
+        ) - tripod_entry_radius - m25_boss_diameter / 2
+]);
+tripod_partition_clearance = partition_y
+    - (tripod_center_y + tripod_entry_radius);
+
 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
-        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);
+rocker_ceiling_z = battery_enabled
+    ? effective_floor + rocker_body_size[2] + fit_clearance
+    : 0;
+body_height = max(electronics_ceiling_z, battery_ceiling_z, rocker_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,
@@ -225,19 +303,121 @@ lid_boss_xy = [
         case_width - wall_thickness - lid_boss_r + lid_boss_wall_overlap
     ]
 ];
+rocker_boss_clearance = min([
+    for (p = lid_boss_xy)
+        sqrt(
+            pow(max(
+                abs(p[0] - rocker_installed_center_x)
+                    - rocker_body_size[0] / 2,
+                0
+            ), 2)
+            + pow(max(
+                abs(p[1] - rocker_installed_center_y)
+                    - rocker_body_size[1] / 2,
+                0
+            ), 2)
+        ) - lid_boss_r
+]);
+rocker_relief_half_size = [
+    rocker_cutout_size[0] / 2,
+    rocker_cutout_size[1] / 2 + rocker_tab_land + rocker_tab_taper_length
+];
+rocker_relief_boss_clearance = min([
+    for (p = lid_boss_xy)
+        sqrt(
+            pow(max(abs(p[0] - rocker_lid_center_x)
+                - rocker_relief_half_size[0], 0), 2)
+            + pow(max(abs(p[1] - rocker_lid_center_y)
+                - rocker_relief_half_size[1], 0), 2)
+        ) - lid_boss_r
+]);
 
 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(battery_partition_thickness >= 1.2,
+    "battery_partition_thickness is too small for 0.6 mm FDM");
+assert(battery_board_clearance > 0,
+    "battery_board_clearance must be positive");
+assert(rocker_tab_panel_thickness >= 1.2,
+    "rocker tab panel needs at least two 0.6 mm lines");
+assert(rocker_tab_panel_thickness < lid_thickness,
+    "rocker tab panel must be thinner than the lid");
+assert(rocker_tab_land > 0 && rocker_tab_taper_length > 0,
+    "rocker tab relief land and taper must be positive");
 assert(lid_lip_thickness >= 1.2, "lid lip needs at least two 0.6 mm lines");
+assert(lid_art_orientation == "usb_left"
+    || lid_art_orientation == "usb_front"
+    || lid_art_orientation == "usb_right"
+    || lid_art_orientation == "usb_rear",
+    "Unsupported lid_art_orientation");
+assert(!lid_artwork_enabled || top_profile != "oled128x64",
+    "Lid artwork is not supported with the OLED profile");
+assert(!lid_artwork_enabled || lid_inlay_depth < lid_thickness,
+    "Lid inlay must be shallower than the lid");
+assert(!lid_artwork_enabled
+    || (lid_art_available_size[0] > 0 && lid_art_available_size[1] > 0),
+    "Lid artwork margin leaves no printable area");
+assert(!lid_logo_enabled || logo_scale > 0,
+    "Lid logo has no printable area");
 assert(m25_boss_diameter > m25_insert_hole_diameter + 2,
     "M2.5 boss does not have enough radial material");
+assert(m25_insert_outer_diameter >= m25_insert_hole_diameter,
+    "M2.5 insert entry must not be smaller than its pilot");
 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");
+assert(!usb_opening_enabled
+    || usb_center_z - usb_reserved_height / 2 >= effective_floor,
+    "USB opening or guide intersects the case floor");
+assert(!usb_opening_enabled
+    || usb_center_z + usb_reserved_height / 2
+        <= body_height - lid_lip_depth,
+    "USB opening or guide intersects the lid lip");
+assert(!tripod_insert_enabled
+    || tripod_insert_outer_diameter >= tripod_insert_hole_diameter,
+    "Tripod insert entry must not be smaller than its pilot");
+assert(!tripod_insert_enabled || tripod_standoff_clearance >= 1.2,
+    "Tripod insert entry is too close to a Feather standoff");
+assert(!battery_enabled || !tripod_insert_enabled
+    || tripod_partition_clearance >= 1,
+    "Tripod insert entry is too close to the battery partition");
+assert(!battery_enabled
+    || rocker_installed_center_x - rocker_body_size[0] / 2
+        >= board_origin_x + feather_length + fit_clearance,
+    "Rocker body overlaps the Feather PCB");
+assert(!battery_enabled
+    || rocker_installed_center_y + rocker_body_size[1] / 2
+        <= partition_y - fit_clearance,
+    "Rocker body overlaps the battery partition");
+assert(!battery_enabled
+    || rocker_installed_center_x - rocker_body_size[0] / 2
+        >= wall_thickness + lid_lip_thickness + fit_clearance,
+    "Rocker body overlaps the front lid lip");
+assert(!battery_enabled
+    || rocker_installed_center_x + rocker_body_size[0] / 2
+        <= case_length - wall_thickness - lid_lip_thickness - fit_clearance,
+    "Rocker body overlaps the rear lid lip");
+assert(!battery_enabled
+    || rocker_installed_center_y - rocker_body_size[1] / 2
+        >= wall_thickness + lid_lip_thickness + fit_clearance,
+    "Rocker body overlaps the Feather-side lid lip");
+assert(!battery_enabled || rocker_boss_clearance >= fit_clearance - eps,
+    "Rocker body overlaps a lid boss");
+assert(!battery_enabled
+    || rocker_relief_boss_clearance >= fit_clearance - eps,
+    "Rocker tab relief overlaps a lid boss scallop");
+assert(!battery_enabled
+    || abs(
+        case_width - rocker_lid_center_y - rocker_installed_center_y
+    ) < eps,
+    "Rocker lid cutout does not mirror to the installed switch location");
+assert(!battery_enabled
+    || body_height - rocker_body_size[2] >= effective_floor,
+    "Rocker body intersects the case floor");
 
 function clamp(v, lo, hi) = min(max(v, lo), hi);
 function cutout_height(entry) = len(entry) > 5 ? entry[5] : entry[4];
@@ -297,8 +477,8 @@ module rounded_box(size, radius) {
         rounded_rect_2d([size[0], size[1]], radius);
 }
 
-module insert_pocket(diameter, depth, entry_z, downward = true) {
+module insert_pocket(diameter, entry_diameter, depth, entry_z, downward = true) {
-    bore_d = diameter + hole_compensation;
+    bore_d = diameter;
     if (downward) {
         translate([0, 0, entry_z - depth])
             cylinder(h = depth + eps, d = bore_d);
@@ -306,7 +486,7 @@ module insert_pocket(diameter, depth, entry_z, downward = true) {
             cylinder(
                 h = insert_entry_chamfer + eps,
                 d1 = bore_d,
-                d2 = bore_d + 2 * insert_entry_chamfer
+                d2 = entry_diameter
             );
     } else {
         translate([0, 0, entry_z - eps])
@@ -314,7 +494,7 @@ module insert_pocket(diameter, depth, entry_z, downward = true) {
         translate([0, 0, entry_z - eps])
             cylinder(
                 h = insert_entry_chamfer + eps,
-                d1 = bore_d + 2 * insert_entry_chamfer,
+                d1 = entry_diameter,
                 d2 = bore_d
             );
     }
@@ -457,20 +637,27 @@ module battery_cradle() {
         battery_end_x - 4
     ];
 
-    // Board/battery partition, with a lead-routing notch near the JST end.
+    // One open-topped front passage provides JST plug access and enough room
+    // to route the battery lead beneath the Feather PCB beside the lid boss.
     difference() {
         translate([wall_thickness, partition_y, effective_floor - eps])
             cube([
                 battery_end_x - wall_thickness + battery_end_clearance,
-                wall_thickness,
+                battery_partition_thickness,
                 partition_height - effective_floor + eps
             ]);
         translate([
-            board_origin_x + 6.5,
+            wall_thickness - eps,
             partition_y - eps,
             effective_floor + 1.5
         ])
-            cube([9, wall_thickness + 2 * eps, 6]);
+            cube([
+                board_origin_x + jst_center_xy[0]
+                    + (jst_body_size[0] + 2 * jst_relief_clearance) / 2
+                    - wall_thickness + 2 * eps,
+                battery_partition_thickness + 2 * eps,
+                partition_height - effective_floor - 1.5 + eps
+            ]);
     }
 
     // Three low curved ribs cradle the protected cylindrical pack.
@@ -501,29 +688,16 @@ module battery_cradle() {
         battery_end_x + battery_end_clearance
     ])
         translate([
-            x,
+            x - eps,
             battery_center_y - battery_diameter / 2 - battery_radial_clearance,
             effective_floor - eps
         ])
             cube([
-                wall_thickness,
+                wall_thickness + 2 * eps,
                 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() {
@@ -542,7 +716,7 @@ module body_positive() {
         if (battery_enabled)
             battery_cradle();
         if (tripod_insert_enabled)
-            translate([case_length / 2, case_width / 2, 0])
+            translate([tripod_center_x, tripod_center_y, 0])
                 cylinder(h = effective_floor, d = tripod_boss_diameter);
         if (usb_guide_active)
             usb_guide_shell();
@@ -555,6 +729,7 @@ module body_cutouts() {
         translate([board_origin_x + mx, board_origin_y + my, 0])
             insert_pocket(
                 m25_insert_hole_diameter,
+                m25_insert_outer_diameter,
                 m25_insert_length + insert_melt_relief,
                 board_bottom_z
             );
@@ -564,6 +739,7 @@ module body_cutouts() {
         translate([p[0], p[1], 0])
             insert_pocket(
                 m25_insert_hole_diameter,
+                m25_insert_outer_diameter,
                 m25_insert_length + insert_melt_relief,
                 body_height
             );
@@ -579,29 +755,8 @@ module body_cutouts() {
             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([tripod_center_x, tripod_center_y, 0]) {
             translate([0, 0, -eps])
                 cylinder(
                     h = effective_floor + 2 * eps,
@@ -609,6 +764,7 @@ module body_cutouts() {
                 );
             insert_pocket(
                 tripod_insert_hole_diameter,
+                tripod_insert_outer_diameter,
                 tripod_insert_length + insert_melt_relief,
                 effective_floor
             );
@@ -702,6 +858,13 @@ module oled_button_lid_cutout(xy) {
 module lid_cutouts() {
     // Through holes plus shallow counterbores for flush M2.5 socket heads.
     for (p = lid_boss_xy) {
+        // Scallop only the locating lip so it can pass over the full-height
+        // insert boss while leaving the lid plate supported by the boss top.
+        translate([p[0], p[1], lid_thickness - eps])
+            cylinder(
+                h = lid_lip_depth + 2 * eps,
+                d = m25_boss_diameter + 2 * fit_clearance
+            );
         translate([p[0], p[1], -eps])
             cylinder(
                 h = lid_thickness + lid_lip_depth + 2 * eps,
@@ -714,6 +877,19 @@ module lid_cutouts() {
             );
     }
 
+    if (battery_enabled) {
+        translate([rocker_lid_center_x, rocker_lid_center_y, -eps])
+            centered_rounded_prism(
+                rocker_cutout_size,
+                lid_thickness + lid_lip_depth + 2 * eps,
+                rocker_corner_radius
+            );
+        rocker_tab_reliefs(
+            [rocker_lid_center_x, rocker_lid_center_y],
+            rocker_cutout_size
+        );
+    }
+
     if (top_profile == "oled128x64") {
         beveled_oled_window();
         if (button_a) oled_button_lid_cutout(oled_button_a_xy);
@@ -723,13 +899,90 @@ module lid_cutouts() {
     }
 }
 
-module lid() {
+// Thin the horizontal top/bottom edges of the upright switch opening where the
+// spring tabs latch. Each full-width land overlaps the rounded opening by its
+// corner radius, then extends outward before tapering to the surrounding lid.
+module rocker_tab_reliefs(center, opening_size) {
+    relief_depth = lid_thickness - rocker_tab_panel_thickness;
+    opening_overlap = rocker_corner_radius;
+    strip = 0.02;
+    for (side = [-1, 1]) {
+        edge_y = center[1] + side * opening_size[1] / 2;
+        translate([
+            center[0] - opening_size[0] / 2,
+            edge_y - (side < 0 ? rocker_tab_land : opening_overlap),
+            rocker_tab_panel_thickness
+        ])
+            cube([opening_size[0], rocker_tab_land + opening_overlap,
+                relief_depth + eps]);
+
+        hull() {
+            translate([
+                center[0] - opening_size[0] / 2,
+                edge_y + side * rocker_tab_land - (side < 0 ? strip : 0),
+                rocker_tab_panel_thickness
+            ])
+                cube([opening_size[0], strip, relief_depth + eps]);
+            translate([
+                center[0] - opening_size[0] / 2,
+                edge_y + side * (rocker_tab_land + rocker_tab_taper_length)
+                    - (side < 0 ? strip : 0),
+                lid_thickness - strip
+            ])
+                cube([opening_size[0], strip, strip + eps]);
+        }
+    }
+}
+
+module lid_artwork_nominal_2d() {
+    translate(lid_art_center)
+        rotate(lid_art_rotation)
+            // The lid is modeled exterior-face-down; mirror the artwork so it
+            // reads normally after the lid is turned into service position.
+            mirror([0, 1, 0]) {
+                if (lid_logo_enabled)
+                    translate([0, lid_logo_center_y])
+                        resize(logo_size)
+                            import(logo_file, center = true);
+                if (lid_label != "")
+                    translate([0, lid_label_center_y])
+                        text(
+                            lid_label,
+                            size = lid_label_size,
+                            halign = "center",
+                            valign = "center",
+                            font = "DejaVu Sans:style=Bold"
+                        );
+            }
+}
+
+module lid_artwork_2d(inset = 0) {
+    offset(delta = inset)
+        lid_artwork_nominal_2d();
+}
+
+module lid_base() {
     difference() {
         lid_plate_positive();
         lid_cutouts();
+        if (lid_artwork_enabled)
+            translate([0, 0, -eps])
+                linear_extrude(height = lid_inlay_depth + eps)
+                    lid_artwork_2d(lid_inlay_fit_clearance);
     }
 }
 
+module lid_accent() {
+    if (lid_artwork_enabled)
+        linear_extrude(height = lid_inlay_depth)
+            lid_artwork_2d();
+}
+
+module lid() {
+    color([0.92, 0.92, 0.95]) lid_base();
+    color([0.95, 0.42, 0.08]) lid_accent();
+}
+
 module one_oled_button() {
     recess_depth = button_flange_thickness + button_travel;
     stem_height = lid_thickness - recess_depth + button_projection;
@@ -769,6 +1022,13 @@ 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([0.92, 0.92, 0.86, 0.9])
+        translate([
+            board_origin_x + jst_center_xy[0] - jst_body_size[0] / 2,
+            board_origin_y + jst_center_xy[1] - 4.5,
+            board_top_z
+        ])
+            cube(jst_body_size);
     color([0.12, 0.45, 0.75, 0.45])
         for (i = [1 : wing_count])
             translate([
@@ -835,19 +1095,20 @@ module reference_battery_and_switch() {
             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])
+        color([0.08, 0.08, 0.08, 0.85])
             translate([
-                switch_center_x,
+                rocker_installed_center_x - rocker_body_size[0] / 2,
-                case_width - wall_thickness,
+                rocker_installed_center_y - rocker_body_size[1] / 2,
-                switch_center_z
+                body_height + exploded_view - rocker_body_size[2]
             ])
-                rotate([90, 0, 0]) {
+                cube(rocker_body_size);
-                    cylinder(h = switch_body_length, d = switch_body_diameter);
+        color([0.12, 0.12, 0.12, 0.95])
-                    translate([0, 0, -1.5])
+            translate([
-                        cylinder(h = 1.5, d = switch_flange_diameter);
+                rocker_installed_center_x - rocker_cutout_size[0] / 2,
-                    translate([0, 0, -3])
+                rocker_installed_center_y - rocker_cutout_size[1] / 2,
-                        cylinder(h = 3, d = switch_cap_diameter);
+                body_height + exploded_view + lid_thickness
-                }
+            ])
+                cube([rocker_cutout_size[0], rocker_cutout_size[1], 2.5]);
     }
 }
 
@@ -865,13 +1126,9 @@ module assembly() {
                 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_length = spacing * len(tripod_coupon_steps) + 8;
     coupon_width = 32;
     coupon_height = max(
         m25_insert_length + insert_melt_relief + 1.2,
@@ -879,17 +1136,21 @@ module insert_coupon() {
     );
     difference() {
         rounded_box([coupon_length, coupon_width, coupon_height], 3);
-        for (i = [0 : len(coupon_steps) - 1]) {
+        for (i = [0 : len(tripod_coupon_steps) - 1]) {
             x = 7 + i * spacing;
-            coupon_hole(
+            translate([x, 8, 0])
-                x, 8,
+                insert_pocket(
-                m25_insert_hole_diameter + coupon_steps[i],
+                    m25_insert_hole_diameter + m25_coupon_steps[i],
-                m25_insert_length + insert_melt_relief
+                    m25_insert_outer_diameter,
+                    m25_insert_length + insert_melt_relief,
+                    coupon_height
                 );
-            coupon_hole(
+            translate([x, 23, 0])
-                x, 23,
+                insert_pocket(
-                tripod_insert_hole_diameter + coupon_steps[i],
+                    tripod_insert_hole_diameter + tripod_coupon_steps[i],
-                tripod_insert_length + insert_melt_relief
+                    tripod_insert_outer_diameter,
+                    tripod_insert_length + insert_melt_relief,
+                    coupon_height
                 );
         }
     }
@@ -898,16 +1159,23 @@ module insert_coupon() {
 module switch_coupon() {
     spacing = 18;
     coupon_length = spacing * len(coupon_steps) + 6;
-    coupon_width = 24;
+    coupon_width = rocker_cutout_size[1] + 6;
-    coupon_height = wall_thickness;
+    coupon_height = lid_thickness;
     difference() {
         rounded_box([coupon_length, coupon_width, coupon_height], 3);
-        for (i = [0 : len(coupon_steps) - 1])
+        for (i = [0 : len(coupon_steps) - 1]) {
             translate([6 + i * spacing, coupon_width / 2, -eps])
-                cylinder(
+                centered_rounded_prism(
-                    h = coupon_height + 2 * eps,
+                    rocker_cutout_size
-                    d = switch_hole_diameter + coupon_steps[i]
+                        + [coupon_steps[i], coupon_steps[i]],
+                    coupon_height + 2 * eps,
+                    rocker_corner_radius
                 );
+            rocker_tab_reliefs(
+                [6 + i * spacing, coupon_width / 2],
+                rocker_cutout_size + [coupon_steps[i], coupon_steps[i]]
+            );
+        }
     }
 }
 
@@ -953,6 +1221,10 @@ else if (part == "body")
     body();
 else if (part == "lid")
     lid();
+else if (part == "lid_base")
+    lid_base();
+else if (part == "lid_accent")
+    lid_accent();
 else if (part == "buttons")
     buttons();
 else if (part == "insert_coupon")

cases/attitude-no-battery/source/render_multicolor_lid.py

@@ -0,0 +1,101 @@
+"""Render aligned lid-base and accent STLs with distinct materials."""
+
+import os
+import sys
+import math
+
+import bpy
+from mathutils import Matrix, Vector
+
+
+def import_mesh(path, name, color):
+    bpy.ops.wm.stl_import(filepath=os.path.abspath(path))
+    model = bpy.context.selected_objects[0]
+    model.name = name
+    material = bpy.data.materials.new(f"{name} material")
+    material.diffuse_color = color
+    material.metallic = 0.0
+    material.roughness = 0.45
+    model.data.materials.append(material)
+    return model
+
+
+def look_at(camera, target):
+    direction = Vector(target) - camera.location
+    camera.rotation_euler = direction.to_track_quat("-Z", "Y").to_euler()
+
+
+def main():
+    args = sys.argv[sys.argv.index("--") + 1 :]
+    if len(args) not in (4, 5):
+        raise SystemExit(
+            "expected: lid-base.stl lid-accent.stl output-directory basename [orientation]"
+        )
+    base_path, accent_path, output_dir, basename = args[:4]
+    orientation = args[4] if len(args) == 5 else "usb_left"
+    angles = {"usb_left": 0, "usb_front": 90, "usb_right": 180, "usb_rear": 270}
+    if orientation not in angles:
+        raise SystemExit(f"unknown lid orientation: {orientation}")
+    os.makedirs(output_dir, exist_ok=True)
+    bpy.ops.wm.read_factory_settings(use_empty=True)
+    models = [
+        import_mesh(base_path, "Lid base", (0.16, 0.42, 0.72, 1.0)),
+        import_mesh(accent_path, "Accent inlays", (0.95, 0.42, 0.08, 1.0)),
+    ]
+    # Lid exports are print-oriented with the decorated exterior face down.
+    # Turn both aligned parts over and present the configured USB edge in its
+    # named position so previews inspect the finished face as the user will.
+    for model in models:
+        model.matrix_world = (
+            Matrix.Rotation(math.radians(angles[orientation]), 4, "Z")
+            @ Matrix.Rotation(math.pi, 4, "X")
+        )
+    bpy.context.view_layer.update()
+
+    corners = [obj.matrix_world @ Vector(corner) for obj in models for corner in obj.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
+    camera.data.type = "ORTHO"
+    camera.data.ortho_scale = span * 1.35
+
+    key_data = bpy.data.lights.new("Key", type="AREA")
+    key_data.energy = 900
+    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)
+
+    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.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"
+
+    for view, direction in {"iso": (1, -1, 0.8), "top": (0, 0, 1)}.items():
+        camera.location = center + Vector(direction).normalized() * span * 2.2
+        look_at(camera, center)
+        scene.render.filepath = os.path.join(output_dir, f"{basename}_{view}.png")
+        bpy.ops.render.render(write_still=True)
+
+
+if __name__ == "__main__":
+    main()

cases/attitude-no-battery/tools/package_multimaterial_3mf.py

@@ -0,0 +1,138 @@
+#!/usr/bin/env python3
+"""Combine aligned lid meshes into one slicer-friendly multipart 3MF."""
+
+from __future__ import annotations
+
+import argparse
+import copy
+import zipfile
+from pathlib import Path
+from xml.etree import ElementTree as ET
+
+
+CORE = "http://schemas.microsoft.com/3dmanufacturing/core/2015/02"
+ET.register_namespace("", CORE)
+
+CONTENT_TYPES_XML = b'''<?xml version="1.0" encoding="UTF-8"?>
+<Types xmlns="http://schemas.openxmlformats.org/package/2006/content-types">
+  <Default Extension="rels" ContentType="application/vnd.openxmlformats-package.relationships+xml"/>
+  <Default Extension="model" ContentType="application/vnd.ms-package.3dmanufacturing-3dmodel+xml"/>
+</Types>
+'''
+
+RELATIONSHIPS_XML = b'''<?xml version="1.0" encoding="UTF-8"?>
+<Relationships xmlns="http://schemas.openxmlformats.org/package/2006/relationships">
+  <Relationship Target="/3D/3dmodel.model" Id="rel0" Type="http://schemas.microsoft.com/3dmanufacturing/2013/01/3dmodel"/>
+</Relationships>
+'''
+
+
+def load_mesh(path: Path) -> ET.Element:
+    with zipfile.ZipFile(path) as archive:
+        root = ET.fromstring(archive.read("3D/3dmodel.model"))
+    mesh = root.find(f".//{{{CORE}}}mesh")
+    if mesh is None:
+        raise ValueError(f"{path} does not contain a 3MF mesh")
+    return copy.deepcopy(mesh)
+
+
+def model_xml(base: Path, accent: Path, title: str) -> bytes:
+    root = ET.Element(
+        f"{{{CORE}}}model",
+        {
+            "unit": "millimeter",
+            "{http://www.w3.org/XML/1998/namespace}lang": "en-US",
+        },
+    )
+    ET.SubElement(root, f"{{{CORE}}}metadata", {"name": "Title"}).text = title
+    ET.SubElement(root, f"{{{CORE}}}metadata", {"name": "Generator"}).text = (
+        "feather-case-wizard"
+    )
+    resources = ET.SubElement(root, f"{{{CORE}}}resources")
+    materials = ET.SubElement(resources, f"{{{CORE}}}basematerials", {"id": "1"})
+    ET.SubElement(
+        materials, f"{{{CORE}}}base", {"name": "Lid base", "displaycolor": "#D1D5DB"}
+    )
+    ET.SubElement(
+        materials,
+        f"{{{CORE}}}base",
+        {"name": "Accent inlays", "displaycolor": "#F97316"},
+    )
+
+    for object_id, name, source in (
+        (2, "Lid base — Filament 1", base),
+        (3, "Accent inlays — Filament 2", accent),
+    ):
+        obj = ET.SubElement(
+            resources,
+            f"{{{CORE}}}object",
+            {
+                "id": str(object_id),
+                "name": name,
+                "type": "model",
+                "pid": "1",
+                "pindex": str(object_id - 2),
+            },
+        )
+        obj.append(load_mesh(source))
+
+    assembly = ET.SubElement(
+        resources, f"{{{CORE}}}object", {"id": "4", "name": title, "type": "model"}
+    )
+    components = ET.SubElement(assembly, f"{{{CORE}}}components")
+    ET.SubElement(components, f"{{{CORE}}}component", {"objectid": "2"})
+    ET.SubElement(components, f"{{{CORE}}}component", {"objectid": "3"})
+    build = ET.SubElement(root, f"{{{CORE}}}build")
+    ET.SubElement(build, f"{{{CORE}}}item", {"objectid": "4"})
+    return ET.tostring(root, encoding="utf-8", xml_declaration=True)
+
+
+def bambu_model_settings_xml(title: str) -> bytes:
+    root = ET.Element("config")
+    obj = ET.SubElement(root, "object", {"id": "4"})
+    ET.SubElement(obj, "metadata", {"key": "name", "value": title})
+    for part_id, name, extruder in (
+        (2, "Lid base — Filament 1", 1),
+        (3, "Accent inlays — Filament 2", 2),
+    ):
+        part = ET.SubElement(obj, "part", {"id": str(part_id), "subtype": "normal_part"})
+        ET.SubElement(part, "metadata", {"key": "name", "value": name})
+        ET.SubElement(part, "metadata", {"key": "extruder", "value": str(extruder)})
+    ET.SubElement(root, "assemble")
+    return ET.tostring(root, encoding="utf-8", xml_declaration=True)
+
+
+def write_entry(archive: zipfile.ZipFile, name: str, data: bytes) -> None:
+    info = zipfile.ZipInfo(name)
+    info.create_system = 3
+    info.external_attr = 0o100644 << 16
+    info.compress_type = zipfile.ZIP_DEFLATED
+    archive.writestr(info, data)
+
+
+def main() -> None:
+    parser = argparse.ArgumentParser()
+    parser.add_argument("base", type=Path)
+    parser.add_argument("accent", type=Path)
+    parser.add_argument("output", type=Path)
+    parser.add_argument("--title", required=True)
+    args = parser.parse_args()
+
+    args.output.parent.mkdir(parents=True, exist_ok=True)
+    with zipfile.ZipFile(args.output, "w", zipfile.ZIP_DEFLATED) as archive:
+        write_entry(archive, "[Content_Types].xml", CONTENT_TYPES_XML)
+        write_entry(archive, "_rels/.rels", RELATIONSHIPS_XML)
+        write_entry(
+            archive,
+            "3D/3dmodel.model",
+            model_xml(args.base, args.accent, args.title),
+        )
+        write_entry(
+            archive,
+            "Metadata/model_settings.config",
+            bambu_model_settings_xml(args.title),
+        )
+
+
+if __name__ == "__main__":
+    main()

cases/attitude-w-battery/README.md

@@ -1,4 +1,4 @@
-# Attitude IMU - Battery
+# Attitude w/battery
 
 Generated by the Feather Case Wizard.
 
@@ -6,19 +6,19 @@ Generated by the Feather Case Wizard.
 - FeatherWings: 1
 - Battery compartment: yes
 - 1/4-20 insert: yes
-- Approximate exterior: 93.9 × 57.3 × 35.8 mm
+- Approximate exterior: 88.6 × 61.1 × 34.4 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
+OpenSCAD, Blender, and Python 3 must be installed. Set `OPENSCAD`,
-override their executable paths.
+`BLENDER`, or `PYTHON` 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
+openscad -p parameters.json -P attitude-w-battery source/feather_case.scad
 ```
 
 The 3MF files contain portable geometry only. Choose printer, filament,

cases/attitude-w-battery/build.rb

@@ -44,13 +44,18 @@ config = YAML.safe_load_file(ROOT.join("case.yml"), permitted_classes: [],
                              permitted_symbols: [], aliases: false)
 openscad = executable("OPENSCAD", "openscad")
 blender = executable("BLENDER", "blender")
+python = executable("PYTHON", "python3")
 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")
 )
+artwork = !parameters.fetch("lid_label", "").empty? ||
+          parameters.fetch("lid_logo_enabled", false)
+abort "Python 3 not found; install it or set PYTHON" if artwork && !python
 parts = %w[body lid] + config.fetch("outputs").fetch("coupons")
+parts.concat(%w[lid_base lid_accent]) if artwork
 buttons = %w[button_a button_b button_c button_reset]
 if parameters["top_profile"] == "oled128x64" &&
    buttons.any? { |name| parameters[name] }
@@ -80,6 +85,16 @@ begin
       puts "Exporting #{part}.#{format}…"
       export.call(directory.join("#{part}.#{format}"), part)
     end
+    if artwork && format == "3mf"
+      puts "Packaging lid_multicolor.3mf…"
+      run!(
+        python, ROOT.join("tools/package_multimaterial_3mf.py").to_s,
+        directory.join("lid_base.3mf").to_s,
+        directory.join("lid_accent.3mf").to_s,
+        directory.join("lid_multicolor.3mf").to_s,
+        "--title", "#{config.fetch("name")} Lid"
+      )
+    end
   end
 
   assembly = scratch.join("assembly.stl")
@@ -97,6 +112,16 @@ begin
     run!(blender, "--background", "-noaudio", "--python", renderer.to_s, "--",
          mesh.to_s, previews.to_s, part, "iso", env: render_env)
   end
+  if artwork
+    puts "Rendering multicolor lid preview…"
+    run!(
+      blender, "--background", "-noaudio", "--python",
+      ROOT.join("source/render_multicolor_lid.py").to_s, "--",
+      scratch.join("lid_base.stl").to_s,
+      scratch.join("lid_accent.stl").to_s,
+      previews.to_s, "lid_multicolor", parameters["lid_art_orientation"], env: render_env
+    )
+  end
 
   backup = ROOT.join(".build-old-#{Process.pid}")
   FileUtils.mkdir_p(backup)

cases/attitude-w-battery/case.yml

@@ -1,9 +1,9 @@
 ---
 schema_version: 1
-name: Attitude IMU - Battery
+name: Attitude w/battery
-slug: attitude-imu-battery
+slug: attitude-w-battery
 generator:
-  sha256: be611e3255e7d802719ebb0628e3d11481f8de05fc96c24d452f026d7b8e3353
+  sha256: 281917098487eeacd19a136ba27752698712e90cb4c03c6525a1ea3167c9ea13
   created_with: feather-case-wizard
 parameters:
   top_profile: generic
@@ -36,20 +36,30 @@ parameters:
   battery_diameter: 18.0
   battery_radial_clearance: 0.6
   battery_end_clearance: 1.0
-  switch_hole_diameter: 12.0
+  battery_partition_thickness: 1.8
-  switch_hole_compensation: 0.3
+  battery_board_clearance: 3.0
-  switch_cap_diameter: 8.0
+  rocker_cutout_size:
-  switch_flange_diameter: 16.2
+  - 12.9
-  switch_body_length: 24.0
+  - 19.4
-  switch_body_diameter: 12.0
+  rocker_corner_radius: 0.8
-  switch_wire_allowance: 3.0
+  rocker_body_size:
+  - 15.0
+  - 21.0
+  - 21.0
+  rocker_artwork_gap: 2.0
+  rocker_partition_offset: 2.0
+  rocker_tab_panel_thickness: 2.0
+  rocker_tab_land: 2.0
+  rocker_tab_taper_length: 0.6
   tripod_insert_enabled: true
-  tripod_insert_length: 6.4
+  tripod_insert_length: 5.0
-  tripod_insert_hole_diameter: 8.8
+  tripod_insert_hole_diameter: 7.2
+  tripod_insert_outer_diameter: 8.0
   tripod_thread_clearance_diameter: 6.8
   tripod_boss_diameter: 14.0
   m25_insert_length: 4.0
-  m25_insert_hole_diameter: 3.7
+  m25_insert_hole_diameter: 3.1
+  m25_insert_outer_diameter: 3.5
   m25_screw_clearance: 2.8
   m25_boss_diameter: 7.0
   insert_entry_chamfer: 0.6
@@ -61,17 +71,31 @@ parameters:
   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_width: 12.5
+  usb_opening_enabled: true
-  usb_opening_height: 7.0
+  usb_guide_enabled: true
+  usb_connector_overhang: 2.0
+  usb_guide_wall_thickness: 1.2
+  usb_guide_end_gap: 1.0
+  lid_label: ''
+  lid_logo_enabled: false
+  lid_art_orientation: usb_left
+  lid_inlay_depth: 0.6
+  lid_inlay_fit_clearance: 0.08
+  lid_label_size: 5.0
+  lid_label_logo_gap: 2.0
+  lid_art_margin: 8.5
+  usb_opening_width: 13.5
+  usb_opening_height: 8.0
   usb_opening_radius: 1.5
-  usb_vertical_offset: 0.0
+  usb_vertical_offset: 0.5
 cutouts: []
 outputs:
   formats:

cases/attitude-w-battery/parameters.json

@@ -1,6 +1,6 @@
 {
   "parameterSets": {
-    "attitude-imu-battery": {
+    "attitude-w-battery": {
       "top_profile": "\"generic\"",
       "wing_count": "1",
       "wing_pitch": "12.25",
@@ -27,20 +27,25 @@
       "battery_diameter": "18.0",
       "battery_radial_clearance": "0.6",
       "battery_end_clearance": "1.0",
-      "switch_hole_diameter": "12.0",
+      "battery_partition_thickness": "1.8",
-      "switch_hole_compensation": "0.3",
+      "battery_board_clearance": "3.0",
-      "switch_cap_diameter": "8.0",
+      "rocker_cutout_size": "[12.9,19.4]",
-      "switch_flange_diameter": "16.2",
+      "rocker_corner_radius": "0.8",
-      "switch_body_length": "24.0",
+      "rocker_body_size": "[15.0,21.0,21.0]",
-      "switch_body_diameter": "12.0",
+      "rocker_artwork_gap": "2.0",
-      "switch_wire_allowance": "3.0",
+      "rocker_partition_offset": "2.0",
+      "rocker_tab_panel_thickness": "2.0",
+      "rocker_tab_land": "2.0",
+      "rocker_tab_taper_length": "0.6",
       "tripod_insert_enabled": "true",
-      "tripod_insert_length": "6.4",
+      "tripod_insert_length": "5.0",
-      "tripod_insert_hole_diameter": "8.8",
+      "tripod_insert_hole_diameter": "7.2",
+      "tripod_insert_outer_diameter": "8.0",
       "tripod_thread_clearance_diameter": "6.8",
       "tripod_boss_diameter": "14.0",
       "m25_insert_length": "4.0",
-      "m25_insert_hole_diameter": "3.7",
+      "m25_insert_hole_diameter": "3.1",
+      "m25_insert_outer_diameter": "3.5",
       "m25_screw_clearance": "2.8",
       "m25_boss_diameter": "7.0",
       "insert_entry_chamfer": "0.6",
@@ -52,17 +57,31 @@
       "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_width": "12.5",
+      "usb_opening_enabled": "true",
-      "usb_opening_height": "7.0",
+      "usb_guide_enabled": "true",
+      "usb_connector_overhang": "2.0",
+      "usb_guide_wall_thickness": "1.2",
+      "usb_guide_end_gap": "1.0",
+      "lid_label": "\"\"",
+      "lid_logo_enabled": "false",
+      "lid_art_orientation": "\"usb_left\"",
+      "lid_inlay_depth": "0.6",
+      "lid_inlay_fit_clearance": "0.08",
+      "lid_label_size": "5.0",
+      "lid_label_logo_gap": "2.0",
+      "lid_art_margin": "8.5",
+      "usb_opening_width": "13.5",
+      "usb_opening_height": "8.0",
       "usb_opening_radius": "1.5",
-      "usb_vertical_offset": "0.0"
+      "usb_vertical_offset": "0.5"
     }
   },
   "fileFormatVersion": "1"

cases/attitude-w-battery/source/assets/NME-fixed.svg

@@ -0,0 +1,82 @@
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+<!-- Created with Inkscape (http://www.inkscape.org/) -->
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+   height="297mm"
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+   xmlns:svg="http://www.w3.org/2000/svg">
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+     pagecolor="#ffffff"
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+     borderopacity="1.0"
+     inkscape:showpageshadow="2"
+     inkscape:pageopacity="0.0"
+     inkscape:pagecheckerboard="0"
+     inkscape:deskcolor="#d1d1d1"
+     inkscape:document-units="mm"
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+     inkscape:zoom="0.914906"
+     inkscape:cx="1166.24"
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+     inkscape:window-height="1390"
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+           style="fill:#000000;stroke:none;stroke-width:0.133333" />
+        <path
+           d="m 134.90261,432.74576 c -0.4,0.93334 -0.53333,27.2 -0.4,58.4 l 0.4,56.53333 38.4,-37.06666 38.26666,-37.06667 -0.26666,-20.93333 -0.4,-20.8 -37.73334,-0.4 c -29.46666,-0.26667 -37.86666,0 -38.26666,1.33333 z"
+           id="path253"
+           style="fill:#000000;stroke:none;stroke-width:0.133333" />
+      </g>
+    </g>
+  </g>
+</svg>

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

@@ -12,7 +12,7 @@
  */
 
 /* [Output] */
-part = "assembly"; // [assembly,body,lid,buttons,insert_coupon,switch_coupon,fit_coupon]
+part = "assembly"; // [assembly,body,lid,lid_base,lid_accent,buttons,insert_coupon,switch_coupon,fit_coupon]
 exploded_view = 8; // [0:1:20]
 show_references = true;
 
@@ -47,24 +47,29 @@ battery_length = 69;
 battery_diameter = 18;
 battery_radial_clearance = 0.6;
 battery_end_clearance = 1;
-switch_hole_diameter = 12;
+battery_partition_thickness = 1.8;
-switch_hole_compensation = 0.3;
+battery_board_clearance = 3;
-switch_cap_diameter = 8;
+rocker_cutout_size = [12.9, 19.4];
-switch_flange_diameter = 16.2;
+rocker_corner_radius = 0.8;
-switch_body_length = 24;
+rocker_body_size = [15, 21, 21];
-switch_body_diameter = 12;
+rocker_artwork_gap = 2;
-switch_wire_allowance = 3;
+rocker_partition_offset = 2;
+rocker_tab_panel_thickness = 2;
+rocker_tab_land = 2;
+rocker_tab_taper_length = 0.6;
 
 /* [Tripod mount] */
 tripod_insert_enabled = false;
-tripod_insert_length = 6.4;
+tripod_insert_length = 5;
-tripod_insert_hole_diameter = 8.8;
+tripod_insert_hole_diameter = 7.2;
+tripod_insert_outer_diameter = 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_insert_hole_diameter = 3.1;
+m25_insert_outer_diameter = 3.5;
 m25_screw_clearance = 2.8;
 m25_boss_diameter = 7;
 insert_entry_chamfer = 0.6;
@@ -78,19 +83,36 @@ 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;
 
+/* [Two-color lid artwork] */
+lid_label = "";
+lid_logo_enabled = false;
+lid_art_orientation = "usb_left"; // [usb_left,usb_front,usb_right,usb_rear]
+lid_inlay_depth = 0.6; // [0.4:0.2:1]
+lid_inlay_fit_clearance = 0.08;
+lid_label_size = 5;
+lid_label_logo_gap = 2;
+lid_art_margin = 8.5;
+logo_file = "assets/NME-fixed.svg";
+
 /* [USB-C opening] */
-usb_opening_width = 12.5;
+usb_opening_enabled = true;
-usb_opening_height = 7;
+usb_guide_enabled = true;
+usb_connector_overhang = 2;
+usb_guide_wall_thickness = 1.2;
+usb_guide_end_gap = 1;
+usb_opening_width = 13.5;
+usb_opening_height = 8;
 usb_opening_radius = 1.5;
-usb_vertical_offset = 0;
+usb_vertical_offset = 0.5;
 
 /* [Custom wall cutouts] */
 // Entry format: [face, shape, u, z, width, height, radius]
@@ -100,6 +122,8 @@ extra_cutouts = [];
 
 /* [Calibration] */
 coupon_steps = [-0.3, -0.15, 0, 0.15, 0.3];
+m25_coupon_steps = [-0.15, -0.075, 0, 0.075, 0.15];
+tripod_coupon_steps = [-0.3, -0.15, 0, 0.15, 0.3];
 
 $fn = $preview ? 36 : 72;
 eps = 0.02;
@@ -111,6 +135,9 @@ board_thickness = 1.6;
 mount_x = [2.54, 48.26];
 mount_y = [2.54, 20.32];
 usb_center_y = 11.43;
+jst_center_xy = [10.9855, 19.304];
+jst_body_size = [8, 7.5, 4.5];
+jst_relief_clearance = 0.5;
 
 // Official 128x64 OLED FeatherWing geometry in Feather-board coordinates.
 oled_visible_min = [11.42, 3.78];
@@ -127,11 +154,34 @@ effective_board_clearance = max(
     board_bottom_clearance,
     m25_insert_length + insert_melt_relief + 0.6
 );
+lid_boss_r = m25_boss_diameter / 2;
+lid_boss_wall_overlap = 0.6;
+front_lid_boss_center = wall_thickness + lid_boss_r
+    - lid_boss_wall_overlap;
+
+// Combined battery/tripod builds need room around the centered insert entry.
+combined_tripod_board_gutter = battery_enabled && tripod_insert_enabled ? 2.4 : 0;
+combined_tripod_x_shift = battery_enabled && tripod_insert_enabled ? 5 : 0;
 
 board_origin_x = wall_thickness + usb_board_wall_gap;
-board_origin_y = wall_thickness + board_side_clearance;
+board_origin_y = wall_thickness + board_side_clearance
+    + combined_tripod_board_gutter;
 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
@@ -146,20 +196,17 @@ profile_top_gap =
     top_profile == "oled128x64" ? oled_face_gap :
     generic_top_gap;
 
-partition_y = board_origin_y + feather_width + 1;
+partition_y = board_origin_y + feather_width + battery_board_clearance;
-battery_center_y = partition_y + wall_thickness + battery_radial_clearance
+battery_center_y = partition_y + battery_partition_thickness
-    + battery_diameter / 2;
+    + battery_radial_clearance + battery_diameter / 2;
-battery_start_x = board_origin_x + battery_end_clearance;
+battery_start_x = front_lid_boss_center + lid_boss_r
+    + 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
+case_length_battery = battery_end_x + battery_end_clearance
-    + 1.2 + wall_thickness;
+    + wall_thickness + m25_boss_diameter - lid_boss_wall_overlap;
 case_length = battery_enabled ? max(case_length_plain, case_length_battery)
     : case_length_plain;
 
@@ -170,23 +217,74 @@ case_width_battery = battery_center_y + battery_diameter / 2
 case_width = battery_enabled ? max(case_width_plain, case_width_battery)
     : case_width_plain;
 
+rocker_installed_center_x = case_length - wall_thickness - fit_clearance
+    - lid_lip_thickness - fit_clearance - rocker_body_size[0] / 2;
+rocker_installed_center_y = front_lid_boss_center + lid_boss_r + fit_clearance
+    + rocker_body_size[1] / 2 + rocker_partition_offset;
+// The printable lid is flipped across Y when installed, so its local cutout
+// coordinate must be mirrored from the assembled switch location.
+rocker_lid_center_x = rocker_installed_center_x;
+rocker_lid_center_y = case_width - rocker_installed_center_y;
+
+lid_artwork_enabled = lid_label != "" || lid_logo_enabled;
+lid_art_rotation =
+    lid_art_orientation == "usb_left" ? 0 :
+    lid_art_orientation == "usb_front" ? 90 :
+    lid_art_orientation == "usb_right" ? 180 : 270;
+lid_art_safe_max_x = battery_enabled
+    ? rocker_lid_center_x - rocker_cutout_size[0] / 2 - rocker_artwork_gap
+    : case_length - lid_art_margin;
+lid_art_physical_size = [
+    lid_art_safe_max_x - lid_art_margin,
+    case_width - 2 * lid_art_margin
+];
+lid_art_center = [
+    lid_art_margin + lid_art_physical_size[0] / 2,
+    case_width / 2
+];
+lid_art_canvas_size = lid_art_rotation == 0 || lid_art_rotation == 180
+    ? lid_art_physical_size
+    : [lid_art_physical_size[1], lid_art_physical_size[0]];
+lid_art_available_size = lid_art_canvas_size;
+lid_label_height = lid_label == "" ? 0 : lid_label_size;
+lid_art_gap = lid_label != "" && lid_logo_enabled ? lid_label_logo_gap : 0;
+logo_native_size = [30, 25.75];
+logo_max_height = lid_art_available_size[1] - lid_label_height - lid_art_gap;
+logo_scale = lid_logo_enabled ? min(
+    lid_art_available_size[0] / logo_native_size[0],
+    logo_max_height / logo_native_size[1]
+) : 0;
+logo_size = [logo_native_size[0] * logo_scale,
+    logo_native_size[1] * logo_scale];
+lid_art_total_height = logo_size[1] + lid_art_gap + lid_label_height;
+lid_label_center_y = -lid_art_total_height / 2 + lid_label_height / 2;
+lid_logo_center_y = -lid_art_total_height / 2 + lid_label_height
+    + lid_art_gap + logo_size[1] / 2;
+
+tripod_center_x = case_length / 2 - combined_tripod_x_shift;
+tripod_center_y = case_width / 2;
+tripod_entry_radius = tripod_insert_outer_diameter / 2;
+tripod_standoff_clearance = min([
+    for (mx = mount_x, my = mount_y)
+        sqrt(
+            pow(board_origin_x + mx - tripod_center_x, 2)
+            + pow(board_origin_y + my - tripod_center_y, 2)
+        ) - tripod_entry_radius - m25_boss_diameter / 2
+]);
+tripod_partition_clearance = partition_y
+    - (tripod_center_y + tripod_entry_radius);
+
 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
-        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);
+rocker_ceiling_z = battery_enabled
+    ? effective_floor + rocker_body_size[2] + fit_clearance
+    : 0;
+body_height = max(electronics_ceiling_z, battery_ceiling_z, rocker_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,
@@ -205,19 +303,156 @@ lid_boss_xy = [
         case_width - wall_thickness - lid_boss_r + lid_boss_wall_overlap
     ]
 ];
+rocker_boss_clearance = min([
+    for (p = lid_boss_xy)
+        sqrt(
+            pow(max(
+                abs(p[0] - rocker_installed_center_x)
+                    - rocker_body_size[0] / 2,
+                0
+            ), 2)
+            + pow(max(
+                abs(p[1] - rocker_installed_center_y)
+                    - rocker_body_size[1] / 2,
+                0
+            ), 2)
+        ) - lid_boss_r
+]);
+rocker_relief_half_size = [
+    rocker_cutout_size[0] / 2,
+    rocker_cutout_size[1] / 2 + rocker_tab_land + rocker_tab_taper_length
+];
+rocker_relief_boss_clearance = min([
+    for (p = lid_boss_xy)
+        sqrt(
+            pow(max(abs(p[0] - rocker_lid_center_x)
+                - rocker_relief_half_size[0], 0), 2)
+            + pow(max(abs(p[1] - rocker_lid_center_y)
+                - rocker_relief_half_size[1], 0), 2)
+        ) - lid_boss_r
+]);
 
 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(battery_partition_thickness >= 1.2,
+    "battery_partition_thickness is too small for 0.6 mm FDM");
+assert(battery_board_clearance > 0,
+    "battery_board_clearance must be positive");
+assert(rocker_tab_panel_thickness >= 1.2,
+    "rocker tab panel needs at least two 0.6 mm lines");
+assert(rocker_tab_panel_thickness < lid_thickness,
+    "rocker tab panel must be thinner than the lid");
+assert(rocker_tab_land > 0 && rocker_tab_taper_length > 0,
+    "rocker tab relief land and taper must be positive");
 assert(lid_lip_thickness >= 1.2, "lid lip needs at least two 0.6 mm lines");
+assert(lid_art_orientation == "usb_left"
+    || lid_art_orientation == "usb_front"
+    || lid_art_orientation == "usb_right"
+    || lid_art_orientation == "usb_rear",
+    "Unsupported lid_art_orientation");
+assert(!lid_artwork_enabled || top_profile != "oled128x64",
+    "Lid artwork is not supported with the OLED profile");
+assert(!lid_artwork_enabled || lid_inlay_depth < lid_thickness,
+    "Lid inlay must be shallower than the lid");
+assert(!lid_artwork_enabled
+    || (lid_art_available_size[0] > 0 && lid_art_available_size[1] > 0),
+    "Lid artwork margin leaves no printable area");
+assert(!lid_logo_enabled || logo_scale > 0,
+    "Lid logo has no printable area");
 assert(m25_boss_diameter > m25_insert_hole_diameter + 2,
     "M2.5 boss does not have enough radial material");
+assert(m25_insert_outer_diameter >= m25_insert_hole_diameter,
+    "M2.5 insert entry must not be smaller than its pilot");
 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");
+assert(!usb_opening_enabled
+    || usb_center_z - usb_reserved_height / 2 >= effective_floor,
+    "USB opening or guide intersects the case floor");
+assert(!usb_opening_enabled
+    || usb_center_z + usb_reserved_height / 2
+        <= body_height - lid_lip_depth,
+    "USB opening or guide intersects the lid lip");
+assert(!tripod_insert_enabled
+    || tripod_insert_outer_diameter >= tripod_insert_hole_diameter,
+    "Tripod insert entry must not be smaller than its pilot");
+assert(!tripod_insert_enabled || tripod_standoff_clearance >= 1.2,
+    "Tripod insert entry is too close to a Feather standoff");
+assert(!battery_enabled || !tripod_insert_enabled
+    || tripod_partition_clearance >= 1,
+    "Tripod insert entry is too close to the battery partition");
+assert(!battery_enabled
+    || rocker_installed_center_x - rocker_body_size[0] / 2
+        >= board_origin_x + feather_length + fit_clearance,
+    "Rocker body overlaps the Feather PCB");
+assert(!battery_enabled
+    || rocker_installed_center_y + rocker_body_size[1] / 2
+        <= partition_y - fit_clearance,
+    "Rocker body overlaps the battery partition");
+assert(!battery_enabled
+    || rocker_installed_center_x - rocker_body_size[0] / 2
+        >= wall_thickness + lid_lip_thickness + fit_clearance,
+    "Rocker body overlaps the front lid lip");
+assert(!battery_enabled
+    || rocker_installed_center_x + rocker_body_size[0] / 2
+        <= case_length - wall_thickness - lid_lip_thickness - fit_clearance,
+    "Rocker body overlaps the rear lid lip");
+assert(!battery_enabled
+    || rocker_installed_center_y - rocker_body_size[1] / 2
+        >= wall_thickness + lid_lip_thickness + fit_clearance,
+    "Rocker body overlaps the Feather-side lid lip");
+assert(!battery_enabled || rocker_boss_clearance >= fit_clearance - eps,
+    "Rocker body overlaps a lid boss");
+assert(!battery_enabled
+    || rocker_relief_boss_clearance >= fit_clearance - eps,
+    "Rocker tab relief overlaps a lid boss scallop");
+assert(!battery_enabled
+    || abs(
+        case_width - rocker_lid_center_y - rocker_installed_center_y
+    ) < eps,
+    "Rocker lid cutout does not mirror to the installed switch location");
+assert(!battery_enabled
+    || body_height - rocker_body_size[2] >= effective_floor,
+    "Rocker body intersects the case floor");
 
 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);
@@ -242,8 +477,8 @@ module rounded_box(size, radius) {
         rounded_rect_2d([size[0], size[1]], radius);
 }
 
-module insert_pocket(diameter, depth, entry_z, downward = true) {
+module insert_pocket(diameter, entry_diameter, depth, entry_z, downward = true) {
-    bore_d = diameter + hole_compensation;
+    bore_d = diameter;
     if (downward) {
         translate([0, 0, entry_z - depth])
             cylinder(h = depth + eps, d = bore_d);
@@ -251,7 +486,7 @@ module insert_pocket(diameter, depth, entry_z, downward = true) {
             cylinder(
                 h = insert_entry_chamfer + eps,
                 d1 = bore_d,
-                d2 = bore_d + 2 * insert_entry_chamfer
+                d2 = entry_diameter
             );
     } else {
         translate([0, 0, entry_z - eps])
@@ -259,7 +494,7 @@ module insert_pocket(diameter, depth, entry_z, downward = true) {
         translate([0, 0, entry_z - eps])
             cylinder(
                 h = insert_entry_chamfer + eps,
-                d1 = bore_d + 2 * insert_entry_chamfer,
+                d1 = entry_diameter,
                 d2 = bore_d
             );
     }
@@ -301,6 +536,40 @@ 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];
@@ -368,20 +637,27 @@ module battery_cradle() {
         battery_end_x - 4
     ];
 
-    // Board/battery partition, with a lead-routing notch near the JST end.
+    // One open-topped front passage provides JST plug access and enough room
+    // to route the battery lead beneath the Feather PCB beside the lid boss.
     difference() {
         translate([wall_thickness, partition_y, effective_floor - eps])
             cube([
                 battery_end_x - wall_thickness + battery_end_clearance,
-                wall_thickness,
+                battery_partition_thickness,
                 partition_height - effective_floor + eps
             ]);
         translate([
-            board_origin_x + 6.5,
+            wall_thickness - eps,
             partition_y - eps,
             effective_floor + 1.5
         ])
-            cube([9, wall_thickness + 2 * eps, 6]);
+            cube([
+                board_origin_x + jst_center_xy[0]
+                    + (jst_body_size[0] + 2 * jst_relief_clearance) / 2
+                    - wall_thickness + 2 * eps,
+                battery_partition_thickness + 2 * eps,
+                partition_height - effective_floor - 1.5 + eps
+            ]);
     }
 
     // Three low curved ribs cradle the protected cylindrical pack.
@@ -412,29 +688,16 @@ module battery_cradle() {
         battery_end_x + battery_end_clearance
     ])
         translate([
-            x,
+            x - eps,
             battery_center_y - battery_diameter / 2 - battery_radial_clearance,
             effective_floor - eps
         ])
             cube([
-                wall_thickness,
+                wall_thickness + 2 * eps,
                 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() {
@@ -453,8 +716,10 @@ module body_positive() {
         if (battery_enabled)
             battery_cradle();
         if (tripod_insert_enabled)
-            translate([case_length / 2, case_width / 2, 0])
+            translate([tripod_center_x, tripod_center_y, 0])
                 cylinder(h = effective_floor, d = tripod_boss_diameter);
+        if (usb_guide_active)
+            usb_guide_shell();
     }
 }
 
@@ -464,6 +729,7 @@ module body_cutouts() {
         translate([board_origin_x + mx, board_origin_y + my, 0])
             insert_pocket(
                 m25_insert_hole_diameter,
+                m25_insert_outer_diameter,
                 m25_insert_length + insert_melt_relief,
                 board_bottom_z
             );
@@ -473,44 +739,24 @@ module body_cutouts() {
         translate([p[0], p[1], 0])
             insert_pocket(
                 m25_insert_hole_diameter,
+                m25_insert_outer_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;
+    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
         );
 
-    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([tripod_center_x, tripod_center_y, 0]) {
             translate([0, 0, -eps])
                 cylinder(
                     h = effective_floor + 2 * eps,
@@ -518,6 +764,7 @@ module body_cutouts() {
                 );
             insert_pocket(
                 tripod_insert_hole_diameter,
+                tripod_insert_outer_diameter,
                 tripod_insert_length + insert_melt_relief,
                 effective_floor
             );
@@ -611,6 +858,13 @@ module oled_button_lid_cutout(xy) {
 module lid_cutouts() {
     // Through holes plus shallow counterbores for flush M2.5 socket heads.
     for (p = lid_boss_xy) {
+        // Scallop only the locating lip so it can pass over the full-height
+        // insert boss while leaving the lid plate supported by the boss top.
+        translate([p[0], p[1], lid_thickness - eps])
+            cylinder(
+                h = lid_lip_depth + 2 * eps,
+                d = m25_boss_diameter + 2 * fit_clearance
+            );
         translate([p[0], p[1], -eps])
             cylinder(
                 h = lid_thickness + lid_lip_depth + 2 * eps,
@@ -623,6 +877,19 @@ module lid_cutouts() {
             );
     }
 
+    if (battery_enabled) {
+        translate([rocker_lid_center_x, rocker_lid_center_y, -eps])
+            centered_rounded_prism(
+                rocker_cutout_size,
+                lid_thickness + lid_lip_depth + 2 * eps,
+                rocker_corner_radius
+            );
+        rocker_tab_reliefs(
+            [rocker_lid_center_x, rocker_lid_center_y],
+            rocker_cutout_size
+        );
+    }
+
     if (top_profile == "oled128x64") {
         beveled_oled_window();
         if (button_a) oled_button_lid_cutout(oled_button_a_xy);
@@ -632,13 +899,90 @@ module lid_cutouts() {
     }
 }
 
-module lid() {
+// Thin the horizontal top/bottom edges of the upright switch opening where the
+// spring tabs latch. Each full-width land overlaps the rounded opening by its
+// corner radius, then extends outward before tapering to the surrounding lid.
+module rocker_tab_reliefs(center, opening_size) {
+    relief_depth = lid_thickness - rocker_tab_panel_thickness;
+    opening_overlap = rocker_corner_radius;
+    strip = 0.02;
+    for (side = [-1, 1]) {
+        edge_y = center[1] + side * opening_size[1] / 2;
+        translate([
+            center[0] - opening_size[0] / 2,
+            edge_y - (side < 0 ? rocker_tab_land : opening_overlap),
+            rocker_tab_panel_thickness
+        ])
+            cube([opening_size[0], rocker_tab_land + opening_overlap,
+                relief_depth + eps]);
+
+        hull() {
+            translate([
+                center[0] - opening_size[0] / 2,
+                edge_y + side * rocker_tab_land - (side < 0 ? strip : 0),
+                rocker_tab_panel_thickness
+            ])
+                cube([opening_size[0], strip, relief_depth + eps]);
+            translate([
+                center[0] - opening_size[0] / 2,
+                edge_y + side * (rocker_tab_land + rocker_tab_taper_length)
+                    - (side < 0 ? strip : 0),
+                lid_thickness - strip
+            ])
+                cube([opening_size[0], strip, strip + eps]);
+        }
+    }
+}
+
+module lid_artwork_nominal_2d() {
+    translate(lid_art_center)
+        rotate(lid_art_rotation)
+            // The lid is modeled exterior-face-down; mirror the artwork so it
+            // reads normally after the lid is turned into service position.
+            mirror([0, 1, 0]) {
+                if (lid_logo_enabled)
+                    translate([0, lid_logo_center_y])
+                        resize(logo_size)
+                            import(logo_file, center = true);
+                if (lid_label != "")
+                    translate([0, lid_label_center_y])
+                        text(
+                            lid_label,
+                            size = lid_label_size,
+                            halign = "center",
+                            valign = "center",
+                            font = "DejaVu Sans:style=Bold"
+                        );
+            }
+}
+
+module lid_artwork_2d(inset = 0) {
+    offset(delta = inset)
+        lid_artwork_nominal_2d();
+}
+
+module lid_base() {
     difference() {
         lid_plate_positive();
         lid_cutouts();
+        if (lid_artwork_enabled)
+            translate([0, 0, -eps])
+                linear_extrude(height = lid_inlay_depth + eps)
+                    lid_artwork_2d(lid_inlay_fit_clearance);
     }
 }
 
+module lid_accent() {
+    if (lid_artwork_enabled)
+        linear_extrude(height = lid_inlay_depth)
+            lid_artwork_2d();
+}
+
+module lid() {
+    color([0.92, 0.92, 0.95]) lid_base();
+    color([0.95, 0.42, 0.08]) lid_accent();
+}
+
 module one_oled_button() {
     recess_depth = button_flange_thickness + button_travel;
     stem_height = lid_thickness - recess_depth + button_projection;
@@ -678,6 +1022,13 @@ 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([0.92, 0.92, 0.86, 0.9])
+        translate([
+            board_origin_x + jst_center_xy[0] - jst_body_size[0] / 2,
+            board_origin_y + jst_center_xy[1] - 4.5,
+            board_top_z
+        ])
+            cube(jst_body_size);
     color([0.12, 0.45, 0.75, 0.45])
         for (i = [1 : wing_count])
             translate([
@@ -744,19 +1095,20 @@ module reference_battery_and_switch() {
             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])
+        color([0.08, 0.08, 0.08, 0.85])
             translate([
-                switch_center_x,
+                rocker_installed_center_x - rocker_body_size[0] / 2,
-                case_width - wall_thickness,
+                rocker_installed_center_y - rocker_body_size[1] / 2,
-                switch_center_z
+                body_height + exploded_view - rocker_body_size[2]
             ])
-                rotate([90, 0, 0]) {
+                cube(rocker_body_size);
-                    cylinder(h = switch_body_length, d = switch_body_diameter);
+        color([0.12, 0.12, 0.12, 0.95])
-                    translate([0, 0, -1.5])
+            translate([
-                        cylinder(h = 1.5, d = switch_flange_diameter);
+                rocker_installed_center_x - rocker_cutout_size[0] / 2,
-                    translate([0, 0, -3])
+                rocker_installed_center_y - rocker_cutout_size[1] / 2,
-                        cylinder(h = 3, d = switch_cap_diameter);
+                body_height + exploded_view + lid_thickness
-                }
+            ])
+                cube([rocker_cutout_size[0], rocker_cutout_size[1], 2.5]);
     }
 }
 
@@ -774,13 +1126,9 @@ module assembly() {
                 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_length = spacing * len(tripod_coupon_steps) + 8;
     coupon_width = 32;
     coupon_height = max(
         m25_insert_length + insert_melt_relief + 1.2,
@@ -788,17 +1136,21 @@ module insert_coupon() {
     );
     difference() {
         rounded_box([coupon_length, coupon_width, coupon_height], 3);
-        for (i = [0 : len(coupon_steps) - 1]) {
+        for (i = [0 : len(tripod_coupon_steps) - 1]) {
             x = 7 + i * spacing;
-            coupon_hole(
+            translate([x, 8, 0])
-                x, 8,
+                insert_pocket(
-                m25_insert_hole_diameter + coupon_steps[i],
+                    m25_insert_hole_diameter + m25_coupon_steps[i],
-                m25_insert_length + insert_melt_relief
+                    m25_insert_outer_diameter,
+                    m25_insert_length + insert_melt_relief,
+                    coupon_height
                 );
-            coupon_hole(
+            translate([x, 23, 0])
-                x, 23,
+                insert_pocket(
-                tripod_insert_hole_diameter + coupon_steps[i],
+                    tripod_insert_hole_diameter + tripod_coupon_steps[i],
-                tripod_insert_length + insert_melt_relief
+                    tripod_insert_outer_diameter,
+                    tripod_insert_length + insert_melt_relief,
+                    coupon_height
                 );
         }
     }
@@ -807,16 +1159,23 @@ module insert_coupon() {
 module switch_coupon() {
     spacing = 18;
     coupon_length = spacing * len(coupon_steps) + 6;
-    coupon_width = 24;
+    coupon_width = rocker_cutout_size[1] + 6;
-    coupon_height = wall_thickness;
+    coupon_height = lid_thickness;
     difference() {
         rounded_box([coupon_length, coupon_width, coupon_height], 3);
-        for (i = [0 : len(coupon_steps) - 1])
+        for (i = [0 : len(coupon_steps) - 1]) {
             translate([6 + i * spacing, coupon_width / 2, -eps])
-                cylinder(
+                centered_rounded_prism(
-                    h = coupon_height + 2 * eps,
+                    rocker_cutout_size
-                    d = switch_hole_diameter + coupon_steps[i]
+                        + [coupon_steps[i], coupon_steps[i]],
+                    coupon_height + 2 * eps,
+                    rocker_corner_radius
                 );
+            rocker_tab_reliefs(
+                [6 + i * spacing, coupon_width / 2],
+                rocker_cutout_size + [coupon_steps[i], coupon_steps[i]]
+            );
+        }
     }
 }
 
@@ -854,12 +1213,18 @@ module fit_coupon() {
         }
 }
 
+validate_cutout_spacing();
+
 if (part == "assembly")
     assembly();
 else if (part == "body")
     body();
 else if (part == "lid")
     lid();
+else if (part == "lid_base")
+    lid_base();
+else if (part == "lid_accent")
+    lid_accent();
 else if (part == "buttons")
     buttons();
 else if (part == "insert_coupon")

cases/attitude-w-battery/source/render_multicolor_lid.py

@@ -0,0 +1,101 @@
+"""Render aligned lid-base and accent STLs with distinct materials."""
+
+import os
+import sys
+import math
+
+import bpy
+from mathutils import Matrix, Vector
+
+
+def import_mesh(path, name, color):
+    bpy.ops.wm.stl_import(filepath=os.path.abspath(path))
+    model = bpy.context.selected_objects[0]
+    model.name = name
+    material = bpy.data.materials.new(f"{name} material")
+    material.diffuse_color = color
+    material.metallic = 0.0
+    material.roughness = 0.45
+    model.data.materials.append(material)
+    return model
+
+
+def look_at(camera, target):
+    direction = Vector(target) - camera.location
+    camera.rotation_euler = direction.to_track_quat("-Z", "Y").to_euler()
+
+
+def main():
+    args = sys.argv[sys.argv.index("--") + 1 :]
+    if len(args) not in (4, 5):
+        raise SystemExit(
+            "expected: lid-base.stl lid-accent.stl output-directory basename [orientation]"
+        )
+    base_path, accent_path, output_dir, basename = args[:4]
+    orientation = args[4] if len(args) == 5 else "usb_left"
+    angles = {"usb_left": 0, "usb_front": 90, "usb_right": 180, "usb_rear": 270}
+    if orientation not in angles:
+        raise SystemExit(f"unknown lid orientation: {orientation}")
+    os.makedirs(output_dir, exist_ok=True)
+    bpy.ops.wm.read_factory_settings(use_empty=True)
+    models = [
+        import_mesh(base_path, "Lid base", (0.16, 0.42, 0.72, 1.0)),
+        import_mesh(accent_path, "Accent inlays", (0.95, 0.42, 0.08, 1.0)),
+    ]
+    # Lid exports are print-oriented with the decorated exterior face down.
+    # Turn both aligned parts over and present the configured USB edge in its
+    # named position so previews inspect the finished face as the user will.
+    for model in models:
+        model.matrix_world = (
+            Matrix.Rotation(math.radians(angles[orientation]), 4, "Z")
+            @ Matrix.Rotation(math.pi, 4, "X")
+        )
+    bpy.context.view_layer.update()
+
+    corners = [obj.matrix_world @ Vector(corner) for obj in models for corner in obj.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
+    camera.data.type = "ORTHO"
+    camera.data.ortho_scale = span * 1.35
+
+    key_data = bpy.data.lights.new("Key", type="AREA")
+    key_data.energy = 900
+    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)
+
+    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.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"
+
+    for view, direction in {"iso": (1, -1, 0.8), "top": (0, 0, 1)}.items():
+        camera.location = center + Vector(direction).normalized() * span * 2.2
+        look_at(camera, center)
+        scene.render.filepath = os.path.join(output_dir, f"{basename}_{view}.png")
+        bpy.ops.render.render(write_still=True)
+
+
+if __name__ == "__main__":
+    main()

cases/attitude-w-battery/tools/package_multimaterial_3mf.py

@@ -0,0 +1,138 @@
+#!/usr/bin/env python3
+"""Combine aligned lid meshes into one slicer-friendly multipart 3MF."""
+
+from __future__ import annotations
+
+import argparse
+import copy
+import zipfile
+from pathlib import Path
+from xml.etree import ElementTree as ET
+
+
+CORE = "http://schemas.microsoft.com/3dmanufacturing/core/2015/02"
+ET.register_namespace("", CORE)
+
+CONTENT_TYPES_XML = b'''<?xml version="1.0" encoding="UTF-8"?>
+<Types xmlns="http://schemas.openxmlformats.org/package/2006/content-types">
+  <Default Extension="rels" ContentType="application/vnd.openxmlformats-package.relationships+xml"/>
+  <Default Extension="model" ContentType="application/vnd.ms-package.3dmanufacturing-3dmodel+xml"/>
+</Types>
+'''
+
+RELATIONSHIPS_XML = b'''<?xml version="1.0" encoding="UTF-8"?>
+<Relationships xmlns="http://schemas.openxmlformats.org/package/2006/relationships">
+  <Relationship Target="/3D/3dmodel.model" Id="rel0" Type="http://schemas.microsoft.com/3dmanufacturing/2013/01/3dmodel"/>
+</Relationships>
+'''
+
+
+def load_mesh(path: Path) -> ET.Element:
+    with zipfile.ZipFile(path) as archive:
+        root = ET.fromstring(archive.read("3D/3dmodel.model"))
+    mesh = root.find(f".//{{{CORE}}}mesh")
+    if mesh is None:
+        raise ValueError(f"{path} does not contain a 3MF mesh")
+    return copy.deepcopy(mesh)
+
+
+def model_xml(base: Path, accent: Path, title: str) -> bytes:
+    root = ET.Element(
+        f"{{{CORE}}}model",
+        {
+            "unit": "millimeter",
+            "{http://www.w3.org/XML/1998/namespace}lang": "en-US",
+        },
+    )
+    ET.SubElement(root, f"{{{CORE}}}metadata", {"name": "Title"}).text = title
+    ET.SubElement(root, f"{{{CORE}}}metadata", {"name": "Generator"}).text = (
+        "feather-case-wizard"
+    )
+    resources = ET.SubElement(root, f"{{{CORE}}}resources")
+    materials = ET.SubElement(resources, f"{{{CORE}}}basematerials", {"id": "1"})
+    ET.SubElement(
+        materials, f"{{{CORE}}}base", {"name": "Lid base", "displaycolor": "#D1D5DB"}
+    )
+    ET.SubElement(
+        materials,
+        f"{{{CORE}}}base",
+        {"name": "Accent inlays", "displaycolor": "#F97316"},
+    )
+
+    for object_id, name, source in (
+        (2, "Lid base — Filament 1", base),
+        (3, "Accent inlays — Filament 2", accent),
+    ):
+        obj = ET.SubElement(
+            resources,
+            f"{{{CORE}}}object",
+            {
+                "id": str(object_id),
+                "name": name,
+                "type": "model",
+                "pid": "1",
+                "pindex": str(object_id - 2),
+            },
+        )
+        obj.append(load_mesh(source))
+
+    assembly = ET.SubElement(
+        resources, f"{{{CORE}}}object", {"id": "4", "name": title, "type": "model"}
+    )
+    components = ET.SubElement(assembly, f"{{{CORE}}}components")
+    ET.SubElement(components, f"{{{CORE}}}component", {"objectid": "2"})
+    ET.SubElement(components, f"{{{CORE}}}component", {"objectid": "3"})
+    build = ET.SubElement(root, f"{{{CORE}}}build")
+    ET.SubElement(build, f"{{{CORE}}}item", {"objectid": "4"})
+    return ET.tostring(root, encoding="utf-8", xml_declaration=True)
+
+
+def bambu_model_settings_xml(title: str) -> bytes:
+    root = ET.Element("config")
+    obj = ET.SubElement(root, "object", {"id": "4"})
+    ET.SubElement(obj, "metadata", {"key": "name", "value": title})
+    for part_id, name, extruder in (
+        (2, "Lid base — Filament 1", 1),
+        (3, "Accent inlays — Filament 2", 2),
+    ):
+        part = ET.SubElement(obj, "part", {"id": str(part_id), "subtype": "normal_part"})
+        ET.SubElement(part, "metadata", {"key": "name", "value": name})
+        ET.SubElement(part, "metadata", {"key": "extruder", "value": str(extruder)})
+    ET.SubElement(root, "assemble")
+    return ET.tostring(root, encoding="utf-8", xml_declaration=True)
+
+
+def write_entry(archive: zipfile.ZipFile, name: str, data: bytes) -> None:
+    info = zipfile.ZipInfo(name)
+    info.create_system = 3
+    info.external_attr = 0o100644 << 16
+    info.compress_type = zipfile.ZIP_DEFLATED
+    archive.writestr(info, data)
+
+
+def main() -> None:
+    parser = argparse.ArgumentParser()
+    parser.add_argument("base", type=Path)
+    parser.add_argument("accent", type=Path)
+    parser.add_argument("output", type=Path)
+    parser.add_argument("--title", required=True)
+    args = parser.parse_args()
+
+    args.output.parent.mkdir(parents=True, exist_ok=True)
+    with zipfile.ZipFile(args.output, "w", zipfile.ZIP_DEFLATED) as archive:
+        write_entry(archive, "[Content_Types].xml", CONTENT_TYPES_XML)
+        write_entry(archive, "_rels/.rels", RELATIONSHIPS_XML)
+        write_entry(
+            archive,
+            "3D/3dmodel.model",
+            model_xml(args.base, args.accent, args.title),
+        )
+        write_entry(
+            archive,
+            "Metadata/model_settings.config",
+            bambu_model_settings_xml(args.title),
+        )
+
+
+if __name__ == "__main__":
+    main()

cases/gps/README.md

@@ -6,14 +6,14 @@ Generated by the Feather Case Wizard.
 - FeatherWings: 1
 - Battery compartment: yes
 - 1/4-20 insert: yes
-- Approximate exterior: 93.9 × 57.3 × 41.8 mm
+- Approximate exterior: 88.6 × 61.1 × 40.4 mm
 - Formats: 3mf
-- Parts: `body`, `lid`, `insert_coupon`, `switch_coupon`, `fit_coupon`
+- Parts: `body`, `lid`, `lid_base`, `lid_accent`, `insert_coupon`, `switch_coupon`, `fit_coupon`
 - 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
+OpenSCAD, Blender, and Python 3 must be installed. Set `OPENSCAD`,
-override their executable paths.
+`BLENDER`, or `PYTHON` to override their executable paths.
 
 To open the saved Customizer values manually:
 
@@ -23,3 +23,9 @@ openscad -p parameters.json -P gps source/feather_case.scad
 
 The 3MF files contain portable geometry only. Choose printer, filament,
 plate, and slicing settings in Bambu Studio.
+
+For a two-color lid, open `exports/3mf/lid_multicolor.3mf` as one
+multipart object. Assign “Lid base — Filament 1” and “Accent inlays —
+Filament 2” to the desired filaments. `lid.3mf` is the complete
+single-color fallback; `lid_base.3mf` and `lid_accent.3mf` are also
+provided separately.

cases/gps/build.rb

@@ -44,13 +44,18 @@ config = YAML.safe_load_file(ROOT.join("case.yml"), permitted_classes: [],
                              permitted_symbols: [], aliases: false)
 openscad = executable("OPENSCAD", "openscad")
 blender = executable("BLENDER", "blender")
+python = executable("PYTHON", "python3")
 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")
 )
+artwork = !parameters.fetch("lid_label", "").empty? ||
+          parameters.fetch("lid_logo_enabled", false)
+abort "Python 3 not found; install it or set PYTHON" if artwork && !python
 parts = %w[body lid] + config.fetch("outputs").fetch("coupons")
+parts.concat(%w[lid_base lid_accent]) if artwork
 buttons = %w[button_a button_b button_c button_reset]
 if parameters["top_profile"] == "oled128x64" &&
    buttons.any? { |name| parameters[name] }
@@ -80,6 +85,16 @@ begin
       puts "Exporting #{part}.#{format}…"
       export.call(directory.join("#{part}.#{format}"), part)
     end
+    if artwork && format == "3mf"
+      puts "Packaging lid_multicolor.3mf…"
+      run!(
+        python, ROOT.join("tools/package_multimaterial_3mf.py").to_s,
+        directory.join("lid_base.3mf").to_s,
+        directory.join("lid_accent.3mf").to_s,
+        directory.join("lid_multicolor.3mf").to_s,
+        "--title", "#{config.fetch("name")} Lid"
+      )
+    end
   end
 
   assembly = scratch.join("assembly.stl")
@@ -97,6 +112,16 @@ begin
     run!(blender, "--background", "-noaudio", "--python", renderer.to_s, "--",
          mesh.to_s, previews.to_s, part, "iso", env: render_env)
   end
+  if artwork
+    puts "Rendering multicolor lid preview…"
+    run!(
+      blender, "--background", "-noaudio", "--python",
+      ROOT.join("source/render_multicolor_lid.py").to_s, "--",
+      scratch.join("lid_base.stl").to_s,
+      scratch.join("lid_accent.stl").to_s,
+      previews.to_s, "lid_multicolor", parameters["lid_art_orientation"], env: render_env
+    )
+  end
 
   backup = ROOT.join(".build-old-#{Process.pid}")
   FileUtils.mkdir_p(backup)

cases/gps/case.yml

@@ -3,7 +3,7 @@ schema_version: 1
 name: GPS
 slug: gps
 generator:
-  sha256: be611e3255e7d802719ebb0628e3d11481f8de05fc96c24d452f026d7b8e3353
+  sha256: 281917098487eeacd19a136ba27752698712e90cb4c03c6525a1ea3167c9ea13
   created_with: feather-case-wizard
 parameters:
   top_profile: gps
@@ -36,20 +36,30 @@ parameters:
   battery_diameter: 18.0
   battery_radial_clearance: 0.6
   battery_end_clearance: 1.0
-  switch_hole_diameter: 12.0
+  battery_partition_thickness: 1.8
-  switch_hole_compensation: 0.3
+  battery_board_clearance: 3.0
-  switch_cap_diameter: 8.0
+  rocker_cutout_size:
-  switch_flange_diameter: 16.2
+  - 12.9
-  switch_body_length: 24.0
+  - 19.4
-  switch_body_diameter: 12.0
+  rocker_corner_radius: 0.8
-  switch_wire_allowance: 3.0
+  rocker_body_size:
+  - 15.0
+  - 21.0
+  - 21.0
+  rocker_artwork_gap: 2.0
+  rocker_partition_offset: 2.0
+  rocker_tab_panel_thickness: 2.0
+  rocker_tab_land: 2.0
+  rocker_tab_taper_length: 0.6
   tripod_insert_enabled: true
-  tripod_insert_length: 6.4
+  tripod_insert_length: 5.0
-  tripod_insert_hole_diameter: 8.8
+  tripod_insert_hole_diameter: 7.2
+  tripod_insert_outer_diameter: 8.0
   tripod_thread_clearance_diameter: 6.8
   tripod_boss_diameter: 14.0
   m25_insert_length: 4.0
-  m25_insert_hole_diameter: 3.7
+  m25_insert_hole_diameter: 3.1
+  m25_insert_outer_diameter: 3.5
   m25_screw_clearance: 2.8
   m25_boss_diameter: 7.0
   insert_entry_chamfer: 0.6
@@ -61,17 +71,31 @@ parameters:
   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_width: 12.5
+  usb_opening_enabled: true
-  usb_opening_height: 7.0
+  usb_guide_enabled: true
+  usb_connector_overhang: 2.0
+  usb_guide_wall_thickness: 1.2
+  usb_guide_end_gap: 1.0
+  lid_label: GPS
+  lid_logo_enabled: true
+  lid_art_orientation: usb_left
+  lid_inlay_depth: 0.6
+  lid_inlay_fit_clearance: 0.08
+  lid_label_size: 5.0
+  lid_label_logo_gap: 2.0
+  lid_art_margin: 8.5
+  usb_opening_width: 13.5
+  usb_opening_height: 8.0
   usb_opening_radius: 1.5
-  usb_vertical_offset: 0.0
+  usb_vertical_offset: 0.5
 cutouts: []
 outputs:
   formats:

cases/gps/parameters.json

@@ -27,20 +27,25 @@
       "battery_diameter": "18.0",
       "battery_radial_clearance": "0.6",
       "battery_end_clearance": "1.0",
-      "switch_hole_diameter": "12.0",
+      "battery_partition_thickness": "1.8",
-      "switch_hole_compensation": "0.3",
+      "battery_board_clearance": "3.0",
-      "switch_cap_diameter": "8.0",
+      "rocker_cutout_size": "[12.9,19.4]",
-      "switch_flange_diameter": "16.2",
+      "rocker_corner_radius": "0.8",
-      "switch_body_length": "24.0",
+      "rocker_body_size": "[15.0,21.0,21.0]",
-      "switch_body_diameter": "12.0",
+      "rocker_artwork_gap": "2.0",
-      "switch_wire_allowance": "3.0",
+      "rocker_partition_offset": "2.0",
+      "rocker_tab_panel_thickness": "2.0",
+      "rocker_tab_land": "2.0",
+      "rocker_tab_taper_length": "0.6",
       "tripod_insert_enabled": "true",
-      "tripod_insert_length": "6.4",
+      "tripod_insert_length": "5.0",
-      "tripod_insert_hole_diameter": "8.8",
+      "tripod_insert_hole_diameter": "7.2",
+      "tripod_insert_outer_diameter": "8.0",
       "tripod_thread_clearance_diameter": "6.8",
       "tripod_boss_diameter": "14.0",
       "m25_insert_length": "4.0",
-      "m25_insert_hole_diameter": "3.7",
+      "m25_insert_hole_diameter": "3.1",
+      "m25_insert_outer_diameter": "3.5",
       "m25_screw_clearance": "2.8",
       "m25_boss_diameter": "7.0",
       "insert_entry_chamfer": "0.6",
@@ -52,17 +57,31 @@
       "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_width": "12.5",
+      "usb_opening_enabled": "true",
-      "usb_opening_height": "7.0",
+      "usb_guide_enabled": "true",
+      "usb_connector_overhang": "2.0",
+      "usb_guide_wall_thickness": "1.2",
+      "usb_guide_end_gap": "1.0",
+      "lid_label": "\"GPS\"",
+      "lid_logo_enabled": "true",
+      "lid_art_orientation": "\"usb_left\"",
+      "lid_inlay_depth": "0.6",
+      "lid_inlay_fit_clearance": "0.08",
+      "lid_label_size": "5.0",
+      "lid_label_logo_gap": "2.0",
+      "lid_art_margin": "8.5",
+      "usb_opening_width": "13.5",
+      "usb_opening_height": "8.0",
       "usb_opening_radius": "1.5",
-      "usb_vertical_offset": "0.0"
+      "usb_vertical_offset": "0.5"
     }
   },
   "fileFormatVersion": "1"

cases/gps/source/assets/NME-fixed.svg

@@ -0,0 +1,82 @@
+<?xml version="1.0" encoding="UTF-8" standalone="no"?>
+<!-- Created with Inkscape (http://www.inkscape.org/) -->
+
+<svg
+   width="210mm"
+   height="297mm"
+   viewBox="0 0 210 297"
+   version="1.1"
+   id="svg584"
+   inkscape:version="1.2.2 (b0a8486541, 2022-12-01)"
+   sodipodi:docname="NME-fixed.svg"
+   xmlns:inkscape="http://www.inkscape.org/namespaces/inkscape"
+   xmlns:sodipodi="http://sodipodi.sourceforge.net/DTD/sodipodi-0.dtd"
+   xmlns="http://www.w3.org/2000/svg"
+   xmlns:svg="http://www.w3.org/2000/svg">
+  <sodipodi:namedview
+     id="namedview586"
+     pagecolor="#ffffff"
+     bordercolor="#666666"
+     borderopacity="1.0"
+     inkscape:showpageshadow="2"
+     inkscape:pageopacity="0.0"
+     inkscape:pagecheckerboard="0"
+     inkscape:deskcolor="#d1d1d1"
+     inkscape:document-units="mm"
+     showgrid="false"
+     inkscape:zoom="0.914906"
+     inkscape:cx="1166.24"
+     inkscape:cy="477.6447"
+     inkscape:window-width="3440"
+     inkscape:window-height="1390"
+     inkscape:window-x="0"
+     inkscape:window-y="1080"
+     inkscape:window-maximized="1"
+     inkscape:current-layer="layer1" />
+  <defs
+     id="defs581" />
+  <g
+     inkscape:label="Layer 1"
+     inkscape:groupmode="layer"
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+    <g
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cases/gps/source/feather_case.scad

@@ -12,7 +12,7 @@
  */
 
 /* [Output] */
-part = "assembly"; // [assembly,body,lid,buttons,insert_coupon,switch_coupon,fit_coupon]
+part = "assembly"; // [assembly,body,lid,lid_base,lid_accent,buttons,insert_coupon,switch_coupon,fit_coupon]
 exploded_view = 8; // [0:1:20]
 show_references = true;
 
@@ -47,24 +47,29 @@ battery_length = 69;
 battery_diameter = 18;
 battery_radial_clearance = 0.6;
 battery_end_clearance = 1;
-switch_hole_diameter = 12;
+battery_partition_thickness = 1.8;
-switch_hole_compensation = 0.3;
+battery_board_clearance = 3;
-switch_cap_diameter = 8;
+rocker_cutout_size = [12.9, 19.4];
-switch_flange_diameter = 16.2;
+rocker_corner_radius = 0.8;
-switch_body_length = 24;
+rocker_body_size = [15, 21, 21];
-switch_body_diameter = 12;
+rocker_artwork_gap = 2;
-switch_wire_allowance = 3;
+rocker_partition_offset = 2;
+rocker_tab_panel_thickness = 2;
+rocker_tab_land = 2;
+rocker_tab_taper_length = 0.6;
 
 /* [Tripod mount] */
 tripod_insert_enabled = false;
-tripod_insert_length = 6.4;
+tripod_insert_length = 5;
-tripod_insert_hole_diameter = 8.8;
+tripod_insert_hole_diameter = 7.2;
+tripod_insert_outer_diameter = 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_insert_hole_diameter = 3.1;
+m25_insert_outer_diameter = 3.5;
 m25_screw_clearance = 2.8;
 m25_boss_diameter = 7;
 insert_entry_chamfer = 0.6;
@@ -78,19 +83,36 @@ 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;
 
+/* [Two-color lid artwork] */
+lid_label = "";
+lid_logo_enabled = false;
+lid_art_orientation = "usb_left"; // [usb_left,usb_front,usb_right,usb_rear]
+lid_inlay_depth = 0.6; // [0.4:0.2:1]
+lid_inlay_fit_clearance = 0.08;
+lid_label_size = 5;
+lid_label_logo_gap = 2;
+lid_art_margin = 8.5;
+logo_file = "assets/NME-fixed.svg";
+
 /* [USB-C opening] */
-usb_opening_width = 12.5;
+usb_opening_enabled = true;
-usb_opening_height = 7;
+usb_guide_enabled = true;
+usb_connector_overhang = 2;
+usb_guide_wall_thickness = 1.2;
+usb_guide_end_gap = 1;
+usb_opening_width = 13.5;
+usb_opening_height = 8;
 usb_opening_radius = 1.5;
-usb_vertical_offset = 0;
+usb_vertical_offset = 0.5;
 
 /* [Custom wall cutouts] */
 // Entry format: [face, shape, u, z, width, height, radius]
@@ -100,6 +122,8 @@ extra_cutouts = [];
 
 /* [Calibration] */
 coupon_steps = [-0.3, -0.15, 0, 0.15, 0.3];
+m25_coupon_steps = [-0.15, -0.075, 0, 0.075, 0.15];
+tripod_coupon_steps = [-0.3, -0.15, 0, 0.15, 0.3];
 
 $fn = $preview ? 36 : 72;
 eps = 0.02;
@@ -111,6 +135,9 @@ board_thickness = 1.6;
 mount_x = [2.54, 48.26];
 mount_y = [2.54, 20.32];
 usb_center_y = 11.43;
+jst_center_xy = [10.9855, 19.304];
+jst_body_size = [8, 7.5, 4.5];
+jst_relief_clearance = 0.5;
 
 // Official 128x64 OLED FeatherWing geometry in Feather-board coordinates.
 oled_visible_min = [11.42, 3.78];
@@ -127,11 +154,34 @@ effective_board_clearance = max(
     board_bottom_clearance,
     m25_insert_length + insert_melt_relief + 0.6
 );
+lid_boss_r = m25_boss_diameter / 2;
+lid_boss_wall_overlap = 0.6;
+front_lid_boss_center = wall_thickness + lid_boss_r
+    - lid_boss_wall_overlap;
+
+// Combined battery/tripod builds need room around the centered insert entry.
+combined_tripod_board_gutter = battery_enabled && tripod_insert_enabled ? 2.4 : 0;
+combined_tripod_x_shift = battery_enabled && tripod_insert_enabled ? 5 : 0;
 
 board_origin_x = wall_thickness + usb_board_wall_gap;
-board_origin_y = wall_thickness + board_side_clearance;
+board_origin_y = wall_thickness + board_side_clearance
+    + combined_tripod_board_gutter;
 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
@@ -146,20 +196,17 @@ profile_top_gap =
     top_profile == "oled128x64" ? oled_face_gap :
     generic_top_gap;
 
-partition_y = board_origin_y + feather_width + 1;
+partition_y = board_origin_y + feather_width + battery_board_clearance;
-battery_center_y = partition_y + wall_thickness + battery_radial_clearance
+battery_center_y = partition_y + battery_partition_thickness
-    + battery_diameter / 2;
+    + battery_radial_clearance + battery_diameter / 2;
-battery_start_x = board_origin_x + battery_end_clearance;
+battery_start_x = front_lid_boss_center + lid_boss_r
+    + 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
+case_length_battery = battery_end_x + battery_end_clearance
-    + 1.2 + wall_thickness;
+    + wall_thickness + m25_boss_diameter - lid_boss_wall_overlap;
 case_length = battery_enabled ? max(case_length_plain, case_length_battery)
     : case_length_plain;
 
@@ -170,23 +217,74 @@ case_width_battery = battery_center_y + battery_diameter / 2
 case_width = battery_enabled ? max(case_width_plain, case_width_battery)
     : case_width_plain;
 
+rocker_installed_center_x = case_length - wall_thickness - fit_clearance
+    - lid_lip_thickness - fit_clearance - rocker_body_size[0] / 2;
+rocker_installed_center_y = front_lid_boss_center + lid_boss_r + fit_clearance
+    + rocker_body_size[1] / 2 + rocker_partition_offset;
+// The printable lid is flipped across Y when installed, so its local cutout
+// coordinate must be mirrored from the assembled switch location.
+rocker_lid_center_x = rocker_installed_center_x;
+rocker_lid_center_y = case_width - rocker_installed_center_y;
+
+lid_artwork_enabled = lid_label != "" || lid_logo_enabled;
+lid_art_rotation =
+    lid_art_orientation == "usb_left" ? 0 :
+    lid_art_orientation == "usb_front" ? 90 :
+    lid_art_orientation == "usb_right" ? 180 : 270;
+lid_art_safe_max_x = battery_enabled
+    ? rocker_lid_center_x - rocker_cutout_size[0] / 2 - rocker_artwork_gap
+    : case_length - lid_art_margin;
+lid_art_physical_size = [
+    lid_art_safe_max_x - lid_art_margin,
+    case_width - 2 * lid_art_margin
+];
+lid_art_center = [
+    lid_art_margin + lid_art_physical_size[0] / 2,
+    case_width / 2
+];
+lid_art_canvas_size = lid_art_rotation == 0 || lid_art_rotation == 180
+    ? lid_art_physical_size
+    : [lid_art_physical_size[1], lid_art_physical_size[0]];
+lid_art_available_size = lid_art_canvas_size;
+lid_label_height = lid_label == "" ? 0 : lid_label_size;
+lid_art_gap = lid_label != "" && lid_logo_enabled ? lid_label_logo_gap : 0;
+logo_native_size = [30, 25.75];
+logo_max_height = lid_art_available_size[1] - lid_label_height - lid_art_gap;
+logo_scale = lid_logo_enabled ? min(
+    lid_art_available_size[0] / logo_native_size[0],
+    logo_max_height / logo_native_size[1]
+) : 0;
+logo_size = [logo_native_size[0] * logo_scale,
+    logo_native_size[1] * logo_scale];
+lid_art_total_height = logo_size[1] + lid_art_gap + lid_label_height;
+lid_label_center_y = -lid_art_total_height / 2 + lid_label_height / 2;
+lid_logo_center_y = -lid_art_total_height / 2 + lid_label_height
+    + lid_art_gap + logo_size[1] / 2;
+
+tripod_center_x = case_length / 2 - combined_tripod_x_shift;
+tripod_center_y = case_width / 2;
+tripod_entry_radius = tripod_insert_outer_diameter / 2;
+tripod_standoff_clearance = min([
+    for (mx = mount_x, my = mount_y)
+        sqrt(
+            pow(board_origin_x + mx - tripod_center_x, 2)
+            + pow(board_origin_y + my - tripod_center_y, 2)
+        ) - tripod_entry_radius - m25_boss_diameter / 2
+]);
+tripod_partition_clearance = partition_y
+    - (tripod_center_y + tripod_entry_radius);
+
 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
-        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);
+rocker_ceiling_z = battery_enabled
+    ? effective_floor + rocker_body_size[2] + fit_clearance
+    : 0;
+body_height = max(electronics_ceiling_z, battery_ceiling_z, rocker_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,
@@ -205,19 +303,156 @@ lid_boss_xy = [
         case_width - wall_thickness - lid_boss_r + lid_boss_wall_overlap
     ]
 ];
+rocker_boss_clearance = min([
+    for (p = lid_boss_xy)
+        sqrt(
+            pow(max(
+                abs(p[0] - rocker_installed_center_x)
+                    - rocker_body_size[0] / 2,
+                0
+            ), 2)
+            + pow(max(
+                abs(p[1] - rocker_installed_center_y)
+                    - rocker_body_size[1] / 2,
+                0
+            ), 2)
+        ) - lid_boss_r
+]);
+rocker_relief_half_size = [
+    rocker_cutout_size[0] / 2,
+    rocker_cutout_size[1] / 2 + rocker_tab_land + rocker_tab_taper_length
+];
+rocker_relief_boss_clearance = min([
+    for (p = lid_boss_xy)
+        sqrt(
+            pow(max(abs(p[0] - rocker_lid_center_x)
+                - rocker_relief_half_size[0], 0), 2)
+            + pow(max(abs(p[1] - rocker_lid_center_y)
+                - rocker_relief_half_size[1], 0), 2)
+        ) - lid_boss_r
+]);
 
 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(battery_partition_thickness >= 1.2,
+    "battery_partition_thickness is too small for 0.6 mm FDM");
+assert(battery_board_clearance > 0,
+    "battery_board_clearance must be positive");
+assert(rocker_tab_panel_thickness >= 1.2,
+    "rocker tab panel needs at least two 0.6 mm lines");
+assert(rocker_tab_panel_thickness < lid_thickness,
+    "rocker tab panel must be thinner than the lid");
+assert(rocker_tab_land > 0 && rocker_tab_taper_length > 0,
+    "rocker tab relief land and taper must be positive");
 assert(lid_lip_thickness >= 1.2, "lid lip needs at least two 0.6 mm lines");
+assert(lid_art_orientation == "usb_left"
+    || lid_art_orientation == "usb_front"
+    || lid_art_orientation == "usb_right"
+    || lid_art_orientation == "usb_rear",
+    "Unsupported lid_art_orientation");
+assert(!lid_artwork_enabled || top_profile != "oled128x64",
+    "Lid artwork is not supported with the OLED profile");
+assert(!lid_artwork_enabled || lid_inlay_depth < lid_thickness,
+    "Lid inlay must be shallower than the lid");
+assert(!lid_artwork_enabled
+    || (lid_art_available_size[0] > 0 && lid_art_available_size[1] > 0),
+    "Lid artwork margin leaves no printable area");
+assert(!lid_logo_enabled || logo_scale > 0,
+    "Lid logo has no printable area");
 assert(m25_boss_diameter > m25_insert_hole_diameter + 2,
     "M2.5 boss does not have enough radial material");
+assert(m25_insert_outer_diameter >= m25_insert_hole_diameter,
+    "M2.5 insert entry must not be smaller than its pilot");
 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");
+assert(!usb_opening_enabled
+    || usb_center_z - usb_reserved_height / 2 >= effective_floor,
+    "USB opening or guide intersects the case floor");
+assert(!usb_opening_enabled
+    || usb_center_z + usb_reserved_height / 2
+        <= body_height - lid_lip_depth,
+    "USB opening or guide intersects the lid lip");
+assert(!tripod_insert_enabled
+    || tripod_insert_outer_diameter >= tripod_insert_hole_diameter,
+    "Tripod insert entry must not be smaller than its pilot");
+assert(!tripod_insert_enabled || tripod_standoff_clearance >= 1.2,
+    "Tripod insert entry is too close to a Feather standoff");
+assert(!battery_enabled || !tripod_insert_enabled
+    || tripod_partition_clearance >= 1,
+    "Tripod insert entry is too close to the battery partition");
+assert(!battery_enabled
+    || rocker_installed_center_x - rocker_body_size[0] / 2
+        >= board_origin_x + feather_length + fit_clearance,
+    "Rocker body overlaps the Feather PCB");
+assert(!battery_enabled
+    || rocker_installed_center_y + rocker_body_size[1] / 2
+        <= partition_y - fit_clearance,
+    "Rocker body overlaps the battery partition");
+assert(!battery_enabled
+    || rocker_installed_center_x - rocker_body_size[0] / 2
+        >= wall_thickness + lid_lip_thickness + fit_clearance,
+    "Rocker body overlaps the front lid lip");
+assert(!battery_enabled
+    || rocker_installed_center_x + rocker_body_size[0] / 2
+        <= case_length - wall_thickness - lid_lip_thickness - fit_clearance,
+    "Rocker body overlaps the rear lid lip");
+assert(!battery_enabled
+    || rocker_installed_center_y - rocker_body_size[1] / 2
+        >= wall_thickness + lid_lip_thickness + fit_clearance,
+    "Rocker body overlaps the Feather-side lid lip");
+assert(!battery_enabled || rocker_boss_clearance >= fit_clearance - eps,
+    "Rocker body overlaps a lid boss");
+assert(!battery_enabled
+    || rocker_relief_boss_clearance >= fit_clearance - eps,
+    "Rocker tab relief overlaps a lid boss scallop");
+assert(!battery_enabled
+    || abs(
+        case_width - rocker_lid_center_y - rocker_installed_center_y
+    ) < eps,
+    "Rocker lid cutout does not mirror to the installed switch location");
+assert(!battery_enabled
+    || body_height - rocker_body_size[2] >= effective_floor,
+    "Rocker body intersects the case floor");
 
 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);
@@ -242,8 +477,8 @@ module rounded_box(size, radius) {
         rounded_rect_2d([size[0], size[1]], radius);
 }
 
-module insert_pocket(diameter, depth, entry_z, downward = true) {
+module insert_pocket(diameter, entry_diameter, depth, entry_z, downward = true) {
-    bore_d = diameter + hole_compensation;
+    bore_d = diameter;
     if (downward) {
         translate([0, 0, entry_z - depth])
             cylinder(h = depth + eps, d = bore_d);
@@ -251,7 +486,7 @@ module insert_pocket(diameter, depth, entry_z, downward = true) {
             cylinder(
                 h = insert_entry_chamfer + eps,
                 d1 = bore_d,
-                d2 = bore_d + 2 * insert_entry_chamfer
+                d2 = entry_diameter
             );
     } else {
         translate([0, 0, entry_z - eps])
@@ -259,7 +494,7 @@ module insert_pocket(diameter, depth, entry_z, downward = true) {
         translate([0, 0, entry_z - eps])
             cylinder(
                 h = insert_entry_chamfer + eps,
-                d1 = bore_d + 2 * insert_entry_chamfer,
+                d1 = entry_diameter,
                 d2 = bore_d
             );
     }
@@ -301,6 +536,40 @@ 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];
@@ -368,20 +637,27 @@ module battery_cradle() {
         battery_end_x - 4
     ];
 
-    // Board/battery partition, with a lead-routing notch near the JST end.
+    // One open-topped front passage provides JST plug access and enough room
+    // to route the battery lead beneath the Feather PCB beside the lid boss.
     difference() {
         translate([wall_thickness, partition_y, effective_floor - eps])
             cube([
                 battery_end_x - wall_thickness + battery_end_clearance,
-                wall_thickness,
+                battery_partition_thickness,
                 partition_height - effective_floor + eps
             ]);
         translate([
-            board_origin_x + 6.5,
+            wall_thickness - eps,
             partition_y - eps,
             effective_floor + 1.5
         ])
-            cube([9, wall_thickness + 2 * eps, 6]);
+            cube([
+                board_origin_x + jst_center_xy[0]
+                    + (jst_body_size[0] + 2 * jst_relief_clearance) / 2
+                    - wall_thickness + 2 * eps,
+                battery_partition_thickness + 2 * eps,
+                partition_height - effective_floor - 1.5 + eps
+            ]);
     }
 
     // Three low curved ribs cradle the protected cylindrical pack.
@@ -412,29 +688,16 @@ module battery_cradle() {
         battery_end_x + battery_end_clearance
     ])
         translate([
-            x,
+            x - eps,
             battery_center_y - battery_diameter / 2 - battery_radial_clearance,
             effective_floor - eps
         ])
             cube([
-                wall_thickness,
+                wall_thickness + 2 * eps,
                 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() {
@@ -453,8 +716,10 @@ module body_positive() {
         if (battery_enabled)
             battery_cradle();
         if (tripod_insert_enabled)
-            translate([case_length / 2, case_width / 2, 0])
+            translate([tripod_center_x, tripod_center_y, 0])
                 cylinder(h = effective_floor, d = tripod_boss_diameter);
+        if (usb_guide_active)
+            usb_guide_shell();
     }
 }
 
@@ -464,6 +729,7 @@ module body_cutouts() {
         translate([board_origin_x + mx, board_origin_y + my, 0])
             insert_pocket(
                 m25_insert_hole_diameter,
+                m25_insert_outer_diameter,
                 m25_insert_length + insert_melt_relief,
                 board_bottom_z
             );
@@ -473,44 +739,24 @@ module body_cutouts() {
         translate([p[0], p[1], 0])
             insert_pocket(
                 m25_insert_hole_diameter,
+                m25_insert_outer_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;
+    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
         );
 
-    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([tripod_center_x, tripod_center_y, 0]) {
             translate([0, 0, -eps])
                 cylinder(
                     h = effective_floor + 2 * eps,
@@ -518,6 +764,7 @@ module body_cutouts() {
                 );
             insert_pocket(
                 tripod_insert_hole_diameter,
+                tripod_insert_outer_diameter,
                 tripod_insert_length + insert_melt_relief,
                 effective_floor
             );
@@ -611,6 +858,13 @@ module oled_button_lid_cutout(xy) {
 module lid_cutouts() {
     // Through holes plus shallow counterbores for flush M2.5 socket heads.
     for (p = lid_boss_xy) {
+        // Scallop only the locating lip so it can pass over the full-height
+        // insert boss while leaving the lid plate supported by the boss top.
+        translate([p[0], p[1], lid_thickness - eps])
+            cylinder(
+                h = lid_lip_depth + 2 * eps,
+                d = m25_boss_diameter + 2 * fit_clearance
+            );
         translate([p[0], p[1], -eps])
             cylinder(
                 h = lid_thickness + lid_lip_depth + 2 * eps,
@@ -623,6 +877,19 @@ module lid_cutouts() {
             );
     }
 
+    if (battery_enabled) {
+        translate([rocker_lid_center_x, rocker_lid_center_y, -eps])
+            centered_rounded_prism(
+                rocker_cutout_size,
+                lid_thickness + lid_lip_depth + 2 * eps,
+                rocker_corner_radius
+            );
+        rocker_tab_reliefs(
+            [rocker_lid_center_x, rocker_lid_center_y],
+            rocker_cutout_size
+        );
+    }
+
     if (top_profile == "oled128x64") {
         beveled_oled_window();
         if (button_a) oled_button_lid_cutout(oled_button_a_xy);
@@ -632,13 +899,90 @@ module lid_cutouts() {
     }
 }
 
-module lid() {
+// Thin the horizontal top/bottom edges of the upright switch opening where the
+// spring tabs latch. Each full-width land overlaps the rounded opening by its
+// corner radius, then extends outward before tapering to the surrounding lid.
+module rocker_tab_reliefs(center, opening_size) {
+    relief_depth = lid_thickness - rocker_tab_panel_thickness;
+    opening_overlap = rocker_corner_radius;
+    strip = 0.02;
+    for (side = [-1, 1]) {
+        edge_y = center[1] + side * opening_size[1] / 2;
+        translate([
+            center[0] - opening_size[0] / 2,
+            edge_y - (side < 0 ? rocker_tab_land : opening_overlap),
+            rocker_tab_panel_thickness
+        ])
+            cube([opening_size[0], rocker_tab_land + opening_overlap,
+                relief_depth + eps]);
+
+        hull() {
+            translate([
+                center[0] - opening_size[0] / 2,
+                edge_y + side * rocker_tab_land - (side < 0 ? strip : 0),
+                rocker_tab_panel_thickness
+            ])
+                cube([opening_size[0], strip, relief_depth + eps]);
+            translate([
+                center[0] - opening_size[0] / 2,
+                edge_y + side * (rocker_tab_land + rocker_tab_taper_length)
+                    - (side < 0 ? strip : 0),
+                lid_thickness - strip
+            ])
+                cube([opening_size[0], strip, strip + eps]);
+        }
+    }
+}
+
+module lid_artwork_nominal_2d() {
+    translate(lid_art_center)
+        rotate(lid_art_rotation)
+            // The lid is modeled exterior-face-down; mirror the artwork so it
+            // reads normally after the lid is turned into service position.
+            mirror([0, 1, 0]) {
+                if (lid_logo_enabled)
+                    translate([0, lid_logo_center_y])
+                        resize(logo_size)
+                            import(logo_file, center = true);
+                if (lid_label != "")
+                    translate([0, lid_label_center_y])
+                        text(
+                            lid_label,
+                            size = lid_label_size,
+                            halign = "center",
+                            valign = "center",
+                            font = "DejaVu Sans:style=Bold"
+                        );
+            }
+}
+
+module lid_artwork_2d(inset = 0) {
+    offset(delta = inset)
+        lid_artwork_nominal_2d();
+}
+
+module lid_base() {
     difference() {
         lid_plate_positive();
         lid_cutouts();
+        if (lid_artwork_enabled)
+            translate([0, 0, -eps])
+                linear_extrude(height = lid_inlay_depth + eps)
+                    lid_artwork_2d(lid_inlay_fit_clearance);
     }
 }
 
+module lid_accent() {
+    if (lid_artwork_enabled)
+        linear_extrude(height = lid_inlay_depth)
+            lid_artwork_2d();
+}
+
+module lid() {
+    color([0.92, 0.92, 0.95]) lid_base();
+    color([0.95, 0.42, 0.08]) lid_accent();
+}
+
 module one_oled_button() {
     recess_depth = button_flange_thickness + button_travel;
     stem_height = lid_thickness - recess_depth + button_projection;
@@ -678,6 +1022,13 @@ 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([0.92, 0.92, 0.86, 0.9])
+        translate([
+            board_origin_x + jst_center_xy[0] - jst_body_size[0] / 2,
+            board_origin_y + jst_center_xy[1] - 4.5,
+            board_top_z
+        ])
+            cube(jst_body_size);
     color([0.12, 0.45, 0.75, 0.45])
         for (i = [1 : wing_count])
             translate([
@@ -744,19 +1095,20 @@ module reference_battery_and_switch() {
             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])
+        color([0.08, 0.08, 0.08, 0.85])
             translate([
-                switch_center_x,
+                rocker_installed_center_x - rocker_body_size[0] / 2,
-                case_width - wall_thickness,
+                rocker_installed_center_y - rocker_body_size[1] / 2,
-                switch_center_z
+                body_height + exploded_view - rocker_body_size[2]
             ])
-                rotate([90, 0, 0]) {
+                cube(rocker_body_size);
-                    cylinder(h = switch_body_length, d = switch_body_diameter);
+        color([0.12, 0.12, 0.12, 0.95])
-                    translate([0, 0, -1.5])
+            translate([
-                        cylinder(h = 1.5, d = switch_flange_diameter);
+                rocker_installed_center_x - rocker_cutout_size[0] / 2,
-                    translate([0, 0, -3])
+                rocker_installed_center_y - rocker_cutout_size[1] / 2,
-                        cylinder(h = 3, d = switch_cap_diameter);
+                body_height + exploded_view + lid_thickness
-                }
+            ])
+                cube([rocker_cutout_size[0], rocker_cutout_size[1], 2.5]);
     }
 }
 
@@ -774,13 +1126,9 @@ module assembly() {
                 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_length = spacing * len(tripod_coupon_steps) + 8;
     coupon_width = 32;
     coupon_height = max(
         m25_insert_length + insert_melt_relief + 1.2,
@@ -788,17 +1136,21 @@ module insert_coupon() {
     );
     difference() {
         rounded_box([coupon_length, coupon_width, coupon_height], 3);
-        for (i = [0 : len(coupon_steps) - 1]) {
+        for (i = [0 : len(tripod_coupon_steps) - 1]) {
             x = 7 + i * spacing;
-            coupon_hole(
+            translate([x, 8, 0])
-                x, 8,
+                insert_pocket(
-                m25_insert_hole_diameter + coupon_steps[i],
+                    m25_insert_hole_diameter + m25_coupon_steps[i],
-                m25_insert_length + insert_melt_relief
+                    m25_insert_outer_diameter,
+                    m25_insert_length + insert_melt_relief,
+                    coupon_height
                 );
-            coupon_hole(
+            translate([x, 23, 0])
-                x, 23,
+                insert_pocket(
-                tripod_insert_hole_diameter + coupon_steps[i],
+                    tripod_insert_hole_diameter + tripod_coupon_steps[i],
-                tripod_insert_length + insert_melt_relief
+                    tripod_insert_outer_diameter,
+                    tripod_insert_length + insert_melt_relief,
+                    coupon_height
                 );
         }
     }
@@ -807,16 +1159,23 @@ module insert_coupon() {
 module switch_coupon() {
     spacing = 18;
     coupon_length = spacing * len(coupon_steps) + 6;
-    coupon_width = 24;
+    coupon_width = rocker_cutout_size[1] + 6;
-    coupon_height = wall_thickness;
+    coupon_height = lid_thickness;
     difference() {
         rounded_box([coupon_length, coupon_width, coupon_height], 3);
-        for (i = [0 : len(coupon_steps) - 1])
+        for (i = [0 : len(coupon_steps) - 1]) {
             translate([6 + i * spacing, coupon_width / 2, -eps])
-                cylinder(
+                centered_rounded_prism(
-                    h = coupon_height + 2 * eps,
+                    rocker_cutout_size
-                    d = switch_hole_diameter + coupon_steps[i]
+                        + [coupon_steps[i], coupon_steps[i]],
+                    coupon_height + 2 * eps,
+                    rocker_corner_radius
                 );
+            rocker_tab_reliefs(
+                [6 + i * spacing, coupon_width / 2],
+                rocker_cutout_size + [coupon_steps[i], coupon_steps[i]]
+            );
+        }
     }
 }
 
@@ -854,12 +1213,18 @@ module fit_coupon() {
         }
 }
 
+validate_cutout_spacing();
+
 if (part == "assembly")
     assembly();
 else if (part == "body")
     body();
 else if (part == "lid")
     lid();
+else if (part == "lid_base")
+    lid_base();
+else if (part == "lid_accent")
+    lid_accent();
 else if (part == "buttons")
     buttons();
 else if (part == "insert_coupon")

cases/gps/source/render_multicolor_lid.py

@@ -0,0 +1,101 @@
+"""Render aligned lid-base and accent STLs with distinct materials."""
+
+import os
+import sys
+import math
+
+import bpy
+from mathutils import Matrix, Vector
+
+
+def import_mesh(path, name, color):
+    bpy.ops.wm.stl_import(filepath=os.path.abspath(path))
+    model = bpy.context.selected_objects[0]
+    model.name = name
+    material = bpy.data.materials.new(f"{name} material")
+    material.diffuse_color = color
+    material.metallic = 0.0
+    material.roughness = 0.45
+    model.data.materials.append(material)
+    return model
+
+
+def look_at(camera, target):
+    direction = Vector(target) - camera.location
+    camera.rotation_euler = direction.to_track_quat("-Z", "Y").to_euler()
+
+
+def main():
+    args = sys.argv[sys.argv.index("--") + 1 :]
+    if len(args) not in (4, 5):
+        raise SystemExit(
+            "expected: lid-base.stl lid-accent.stl output-directory basename [orientation]"
+        )
+    base_path, accent_path, output_dir, basename = args[:4]
+    orientation = args[4] if len(args) == 5 else "usb_left"
+    angles = {"usb_left": 0, "usb_front": 90, "usb_right": 180, "usb_rear": 270}
+    if orientation not in angles:
+        raise SystemExit(f"unknown lid orientation: {orientation}")
+    os.makedirs(output_dir, exist_ok=True)
+    bpy.ops.wm.read_factory_settings(use_empty=True)
+    models = [
+        import_mesh(base_path, "Lid base", (0.16, 0.42, 0.72, 1.0)),
+        import_mesh(accent_path, "Accent inlays", (0.95, 0.42, 0.08, 1.0)),
+    ]
+    # Lid exports are print-oriented with the decorated exterior face down.
+    # Turn both aligned parts over and present the configured USB edge in its
+    # named position so previews inspect the finished face as the user will.
+    for model in models:
+        model.matrix_world = (
+            Matrix.Rotation(math.radians(angles[orientation]), 4, "Z")
+            @ Matrix.Rotation(math.pi, 4, "X")
+        )
+    bpy.context.view_layer.update()
+
+    corners = [obj.matrix_world @ Vector(corner) for obj in models for corner in obj.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
+    camera.data.type = "ORTHO"
+    camera.data.ortho_scale = span * 1.35
+
+    key_data = bpy.data.lights.new("Key", type="AREA")
+    key_data.energy = 900
+    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)
+
+    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.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"
+
+    for view, direction in {"iso": (1, -1, 0.8), "top": (0, 0, 1)}.items():
+        camera.location = center + Vector(direction).normalized() * span * 2.2
+        look_at(camera, center)
+        scene.render.filepath = os.path.join(output_dir, f"{basename}_{view}.png")
+        bpy.ops.render.render(write_still=True)
+
+
+if __name__ == "__main__":
+    main()

cases/gps/tools/package_multimaterial_3mf.py

@@ -0,0 +1,138 @@
+#!/usr/bin/env python3
+"""Combine aligned lid meshes into one slicer-friendly multipart 3MF."""
+
+from __future__ import annotations
+
+import argparse
+import copy
+import zipfile
+from pathlib import Path
+from xml.etree import ElementTree as ET
+
+
+CORE = "http://schemas.microsoft.com/3dmanufacturing/core/2015/02"
+ET.register_namespace("", CORE)
+
+CONTENT_TYPES_XML = b'''<?xml version="1.0" encoding="UTF-8"?>
+<Types xmlns="http://schemas.openxmlformats.org/package/2006/content-types">
+  <Default Extension="rels" ContentType="application/vnd.openxmlformats-package.relationships+xml"/>
+  <Default Extension="model" ContentType="application/vnd.ms-package.3dmanufacturing-3dmodel+xml"/>
+</Types>
+'''
+
+RELATIONSHIPS_XML = b'''<?xml version="1.0" encoding="UTF-8"?>
+<Relationships xmlns="http://schemas.openxmlformats.org/package/2006/relationships">
+  <Relationship Target="/3D/3dmodel.model" Id="rel0" Type="http://schemas.microsoft.com/3dmanufacturing/2013/01/3dmodel"/>
+</Relationships>
+'''
+
+
+def load_mesh(path: Path) -> ET.Element:
+    with zipfile.ZipFile(path) as archive:
+        root = ET.fromstring(archive.read("3D/3dmodel.model"))
+    mesh = root.find(f".//{{{CORE}}}mesh")
+    if mesh is None:
+        raise ValueError(f"{path} does not contain a 3MF mesh")
+    return copy.deepcopy(mesh)
+
+
+def model_xml(base: Path, accent: Path, title: str) -> bytes:
+    root = ET.Element(
+        f"{{{CORE}}}model",
+        {
+            "unit": "millimeter",
+            "{http://www.w3.org/XML/1998/namespace}lang": "en-US",
+        },
+    )
+    ET.SubElement(root, f"{{{CORE}}}metadata", {"name": "Title"}).text = title
+    ET.SubElement(root, f"{{{CORE}}}metadata", {"name": "Generator"}).text = (
+        "feather-case-wizard"
+    )
+    resources = ET.SubElement(root, f"{{{CORE}}}resources")
+    materials = ET.SubElement(resources, f"{{{CORE}}}basematerials", {"id": "1"})
+    ET.SubElement(
+        materials, f"{{{CORE}}}base", {"name": "Lid base", "displaycolor": "#D1D5DB"}
+    )
+    ET.SubElement(
+        materials,
+        f"{{{CORE}}}base",
+        {"name": "Accent inlays", "displaycolor": "#F97316"},
+    )
+
+    for object_id, name, source in (
+        (2, "Lid base — Filament 1", base),
+        (3, "Accent inlays — Filament 2", accent),
+    ):
+        obj = ET.SubElement(
+            resources,
+            f"{{{CORE}}}object",
+            {
+                "id": str(object_id),
+                "name": name,
+                "type": "model",
+                "pid": "1",
+                "pindex": str(object_id - 2),
+            },
+        )
+        obj.append(load_mesh(source))
+
+    assembly = ET.SubElement(
+        resources, f"{{{CORE}}}object", {"id": "4", "name": title, "type": "model"}
+    )
+    components = ET.SubElement(assembly, f"{{{CORE}}}components")
+    ET.SubElement(components, f"{{{CORE}}}component", {"objectid": "2"})
+    ET.SubElement(components, f"{{{CORE}}}component", {"objectid": "3"})
+    build = ET.SubElement(root, f"{{{CORE}}}build")
+    ET.SubElement(build, f"{{{CORE}}}item", {"objectid": "4"})
+    return ET.tostring(root, encoding="utf-8", xml_declaration=True)
+
+
+def bambu_model_settings_xml(title: str) -> bytes:
+    root = ET.Element("config")
+    obj = ET.SubElement(root, "object", {"id": "4"})
+    ET.SubElement(obj, "metadata", {"key": "name", "value": title})
+    for part_id, name, extruder in (
+        (2, "Lid base — Filament 1", 1),
+        (3, "Accent inlays — Filament 2", 2),
+    ):
+        part = ET.SubElement(obj, "part", {"id": str(part_id), "subtype": "normal_part"})
+        ET.SubElement(part, "metadata", {"key": "name", "value": name})
+        ET.SubElement(part, "metadata", {"key": "extruder", "value": str(extruder)})
+    ET.SubElement(root, "assemble")
+    return ET.tostring(root, encoding="utf-8", xml_declaration=True)
+
+
+def write_entry(archive: zipfile.ZipFile, name: str, data: bytes) -> None:
+    info = zipfile.ZipInfo(name)
+    info.create_system = 3
+    info.external_attr = 0o100644 << 16
+    info.compress_type = zipfile.ZIP_DEFLATED
+    archive.writestr(info, data)
+
+
+def main() -> None:
+    parser = argparse.ArgumentParser()
+    parser.add_argument("base", type=Path)
+    parser.add_argument("accent", type=Path)
+    parser.add_argument("output", type=Path)
+    parser.add_argument("--title", required=True)
+    args = parser.parse_args()
+
+    args.output.parent.mkdir(parents=True, exist_ok=True)
+    with zipfile.ZipFile(args.output, "w", zipfile.ZIP_DEFLATED) as archive:
+        write_entry(archive, "[Content_Types].xml", CONTENT_TYPES_XML)
+        write_entry(archive, "_rels/.rels", RELATIONSHIPS_XML)
+        write_entry(
+            archive,
+            "3D/3dmodel.model",
+            model_xml(args.base, args.accent, args.title),
+        )
+        write_entry(
+            archive,
+            "Metadata/model_settings.config",
+            bambu_model_settings_xml(args.title),
+        )
+
+
+if __name__ == "__main__":
+    main()

cases/pan-tilt-head/README.md

@@ -1,25 +0,0 @@
-# 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

@@ -1,123 +0,0 @@
-#!/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

@@ -1,148 +0,0 @@
----
-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/source/render_stl_previews.py

@@ -1,127 +0,0 @@
-"""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

@@ -12,7 +12,7 @@
  */
 
 /* [Output] */
-part = "assembly"; // [assembly,body,lid,buttons,insert_coupon,switch_coupon,fit_coupon]
+part = "assembly"; // [assembly,body,lid,lid_base,lid_accent,buttons,insert_coupon,switch_coupon,fit_coupon]
 exploded_view = 8; // [0:1:20]
 show_references = true;
 
@@ -47,24 +47,29 @@ battery_length = 69;
 battery_diameter = 18;
 battery_radial_clearance = 0.6;
 battery_end_clearance = 1;
-switch_hole_diameter = 12;
+battery_partition_thickness = 1.8;
-switch_hole_compensation = 0.3;
+battery_board_clearance = 3;
-switch_cap_diameter = 8;
+rocker_cutout_size = [12.9, 19.4];
-switch_flange_diameter = 16.2;
+rocker_corner_radius = 0.8;
-switch_body_length = 24;
+rocker_body_size = [15, 21, 21];
-switch_body_diameter = 12;
+rocker_artwork_gap = 2;
-switch_wire_allowance = 3;
+rocker_partition_offset = 2;
+rocker_tab_panel_thickness = 2;
+rocker_tab_land = 2;
+rocker_tab_taper_length = 0.6;
 
 /* [Tripod mount] */
 tripod_insert_enabled = false;
-tripod_insert_length = 6.4;
+tripod_insert_length = 5;
-tripod_insert_hole_diameter = 8.8;
+tripod_insert_hole_diameter = 7.2;
+tripod_insert_outer_diameter = 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_insert_hole_diameter = 3.1;
+m25_insert_outer_diameter = 3.5;
 m25_screw_clearance = 2.8;
 m25_boss_diameter = 7;
 insert_entry_chamfer = 0.6;
@@ -87,16 +92,27 @@ hole_compensation = 0.2;
 lid_screw_head_diameter = 5.2;
 lid_screw_head_height = 2.5;
 
+/* [Two-color lid artwork] */
+lid_label = "";
+lid_logo_enabled = false;
+lid_art_orientation = "usb_left"; // [usb_left,usb_front,usb_right,usb_rear]
+lid_inlay_depth = 0.6; // [0.4:0.2:1]
+lid_inlay_fit_clearance = 0.08;
+lid_label_size = 5;
+lid_label_logo_gap = 2;
+lid_art_margin = 8.5;
+logo_file = "assets/NME-fixed.svg";
+
 /* [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_width = 13.5;
-usb_opening_height = 7;
+usb_opening_height = 8;
 usb_opening_radius = 1.5;
-usb_vertical_offset = 0;
+usb_vertical_offset = 0.5;
 
 /* [Custom wall cutouts] */
 // Entry format: [face, shape, u, z, width, height, radius]
@@ -106,6 +122,8 @@ extra_cutouts = [];
 
 /* [Calibration] */
 coupon_steps = [-0.3, -0.15, 0, 0.15, 0.3];
+m25_coupon_steps = [-0.15, -0.075, 0, 0.075, 0.15];
+tripod_coupon_steps = [-0.3, -0.15, 0, 0.15, 0.3];
 
 $fn = $preview ? 36 : 72;
 eps = 0.02;
@@ -117,6 +135,9 @@ board_thickness = 1.6;
 mount_x = [2.54, 48.26];
 mount_y = [2.54, 20.32];
 usb_center_y = 11.43;
+jst_center_xy = [10.9855, 19.304];
+jst_body_size = [8, 7.5, 4.5];
+jst_relief_clearance = 0.5;
 
 // Official 128x64 OLED FeatherWing geometry in Feather-board coordinates.
 oled_visible_min = [11.42, 3.78];
@@ -133,9 +154,18 @@ effective_board_clearance = max(
     board_bottom_clearance,
     m25_insert_length + insert_melt_relief + 0.6
 );
+lid_boss_r = m25_boss_diameter / 2;
+lid_boss_wall_overlap = 0.6;
+front_lid_boss_center = wall_thickness + lid_boss_r
+    - lid_boss_wall_overlap;
+
+// Combined battery/tripod builds need room around the centered insert entry.
+combined_tripod_board_gutter = battery_enabled && tripod_insert_enabled ? 2.4 : 0;
+combined_tripod_x_shift = battery_enabled && tripod_insert_enabled ? 5 : 0;
 
 board_origin_x = wall_thickness + usb_board_wall_gap;
-board_origin_y = wall_thickness + board_side_clearance;
+board_origin_y = wall_thickness + board_side_clearance
+    + combined_tripod_board_gutter;
 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;
@@ -166,20 +196,17 @@ profile_top_gap =
     top_profile == "oled128x64" ? oled_face_gap :
     generic_top_gap;
 
-partition_y = board_origin_y + feather_width + 1;
+partition_y = board_origin_y + feather_width + battery_board_clearance;
-battery_center_y = partition_y + wall_thickness + battery_radial_clearance
+battery_center_y = partition_y + battery_partition_thickness
-    + battery_diameter / 2;
+    + battery_radial_clearance + battery_diameter / 2;
-battery_start_x = board_origin_x + battery_end_clearance;
+battery_start_x = front_lid_boss_center + lid_boss_r
+    + 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
+case_length_battery = battery_end_x + battery_end_clearance
-    + 1.2 + wall_thickness;
+    + wall_thickness + m25_boss_diameter - lid_boss_wall_overlap;
 case_length = battery_enabled ? max(case_length_plain, case_length_battery)
     : case_length_plain;
 
@@ -190,23 +217,74 @@ case_width_battery = battery_center_y + battery_diameter / 2
 case_width = battery_enabled ? max(case_width_plain, case_width_battery)
     : case_width_plain;
 
+rocker_installed_center_x = case_length - wall_thickness - fit_clearance
+    - lid_lip_thickness - fit_clearance - rocker_body_size[0] / 2;
+rocker_installed_center_y = front_lid_boss_center + lid_boss_r + fit_clearance
+    + rocker_body_size[1] / 2 + rocker_partition_offset;
+// The printable lid is flipped across Y when installed, so its local cutout
+// coordinate must be mirrored from the assembled switch location.
+rocker_lid_center_x = rocker_installed_center_x;
+rocker_lid_center_y = case_width - rocker_installed_center_y;
+
+lid_artwork_enabled = lid_label != "" || lid_logo_enabled;
+lid_art_rotation =
+    lid_art_orientation == "usb_left" ? 0 :
+    lid_art_orientation == "usb_front" ? 90 :
+    lid_art_orientation == "usb_right" ? 180 : 270;
+lid_art_safe_max_x = battery_enabled
+    ? rocker_lid_center_x - rocker_cutout_size[0] / 2 - rocker_artwork_gap
+    : case_length - lid_art_margin;
+lid_art_physical_size = [
+    lid_art_safe_max_x - lid_art_margin,
+    case_width - 2 * lid_art_margin
+];
+lid_art_center = [
+    lid_art_margin + lid_art_physical_size[0] / 2,
+    case_width / 2
+];
+lid_art_canvas_size = lid_art_rotation == 0 || lid_art_rotation == 180
+    ? lid_art_physical_size
+    : [lid_art_physical_size[1], lid_art_physical_size[0]];
+lid_art_available_size = lid_art_canvas_size;
+lid_label_height = lid_label == "" ? 0 : lid_label_size;
+lid_art_gap = lid_label != "" && lid_logo_enabled ? lid_label_logo_gap : 0;
+logo_native_size = [30, 25.75];
+logo_max_height = lid_art_available_size[1] - lid_label_height - lid_art_gap;
+logo_scale = lid_logo_enabled ? min(
+    lid_art_available_size[0] / logo_native_size[0],
+    logo_max_height / logo_native_size[1]
+) : 0;
+logo_size = [logo_native_size[0] * logo_scale,
+    logo_native_size[1] * logo_scale];
+lid_art_total_height = logo_size[1] + lid_art_gap + lid_label_height;
+lid_label_center_y = -lid_art_total_height / 2 + lid_label_height / 2;
+lid_logo_center_y = -lid_art_total_height / 2 + lid_label_height
+    + lid_art_gap + logo_size[1] / 2;
+
+tripod_center_x = case_length / 2 - combined_tripod_x_shift;
+tripod_center_y = case_width / 2;
+tripod_entry_radius = tripod_insert_outer_diameter / 2;
+tripod_standoff_clearance = min([
+    for (mx = mount_x, my = mount_y)
+        sqrt(
+            pow(board_origin_x + mx - tripod_center_x, 2)
+            + pow(board_origin_y + my - tripod_center_y, 2)
+        ) - tripod_entry_radius - m25_boss_diameter / 2
+]);
+tripod_partition_clearance = partition_y
+    - (tripod_center_y + tripod_entry_radius);
+
 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
-        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);
+rocker_ceiling_z = battery_enabled
+    ? effective_floor + rocker_body_size[2] + fit_clearance
+    : 0;
+body_height = max(electronics_ceiling_z, battery_ceiling_z, rocker_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,
@@ -225,19 +303,121 @@ lid_boss_xy = [
         case_width - wall_thickness - lid_boss_r + lid_boss_wall_overlap
     ]
 ];
+rocker_boss_clearance = min([
+    for (p = lid_boss_xy)
+        sqrt(
+            pow(max(
+                abs(p[0] - rocker_installed_center_x)
+                    - rocker_body_size[0] / 2,
+                0
+            ), 2)
+            + pow(max(
+                abs(p[1] - rocker_installed_center_y)
+                    - rocker_body_size[1] / 2,
+                0
+            ), 2)
+        ) - lid_boss_r
+]);
+rocker_relief_half_size = [
+    rocker_cutout_size[0] / 2,
+    rocker_cutout_size[1] / 2 + rocker_tab_land + rocker_tab_taper_length
+];
+rocker_relief_boss_clearance = min([
+    for (p = lid_boss_xy)
+        sqrt(
+            pow(max(abs(p[0] - rocker_lid_center_x)
+                - rocker_relief_half_size[0], 0), 2)
+            + pow(max(abs(p[1] - rocker_lid_center_y)
+                - rocker_relief_half_size[1], 0), 2)
+        ) - lid_boss_r
+]);
 
 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(battery_partition_thickness >= 1.2,
+    "battery_partition_thickness is too small for 0.6 mm FDM");
+assert(battery_board_clearance > 0,
+    "battery_board_clearance must be positive");
+assert(rocker_tab_panel_thickness >= 1.2,
+    "rocker tab panel needs at least two 0.6 mm lines");
+assert(rocker_tab_panel_thickness < lid_thickness,
+    "rocker tab panel must be thinner than the lid");
+assert(rocker_tab_land > 0 && rocker_tab_taper_length > 0,
+    "rocker tab relief land and taper must be positive");
 assert(lid_lip_thickness >= 1.2, "lid lip needs at least two 0.6 mm lines");
+assert(lid_art_orientation == "usb_left"
+    || lid_art_orientation == "usb_front"
+    || lid_art_orientation == "usb_right"
+    || lid_art_orientation == "usb_rear",
+    "Unsupported lid_art_orientation");
+assert(!lid_artwork_enabled || top_profile != "oled128x64",
+    "Lid artwork is not supported with the OLED profile");
+assert(!lid_artwork_enabled || lid_inlay_depth < lid_thickness,
+    "Lid inlay must be shallower than the lid");
+assert(!lid_artwork_enabled
+    || (lid_art_available_size[0] > 0 && lid_art_available_size[1] > 0),
+    "Lid artwork margin leaves no printable area");
+assert(!lid_logo_enabled || logo_scale > 0,
+    "Lid logo has no printable area");
 assert(m25_boss_diameter > m25_insert_hole_diameter + 2,
     "M2.5 boss does not have enough radial material");
+assert(m25_insert_outer_diameter >= m25_insert_hole_diameter,
+    "M2.5 insert entry must not be smaller than its pilot");
 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");
+assert(!usb_opening_enabled
+    || usb_center_z - usb_reserved_height / 2 >= effective_floor,
+    "USB opening or guide intersects the case floor");
+assert(!usb_opening_enabled
+    || usb_center_z + usb_reserved_height / 2
+        <= body_height - lid_lip_depth,
+    "USB opening or guide intersects the lid lip");
+assert(!tripod_insert_enabled
+    || tripod_insert_outer_diameter >= tripod_insert_hole_diameter,
+    "Tripod insert entry must not be smaller than its pilot");
+assert(!tripod_insert_enabled || tripod_standoff_clearance >= 1.2,
+    "Tripod insert entry is too close to a Feather standoff");
+assert(!battery_enabled || !tripod_insert_enabled
+    || tripod_partition_clearance >= 1,
+    "Tripod insert entry is too close to the battery partition");
+assert(!battery_enabled
+    || rocker_installed_center_x - rocker_body_size[0] / 2
+        >= board_origin_x + feather_length + fit_clearance,
+    "Rocker body overlaps the Feather PCB");
+assert(!battery_enabled
+    || rocker_installed_center_y + rocker_body_size[1] / 2
+        <= partition_y - fit_clearance,
+    "Rocker body overlaps the battery partition");
+assert(!battery_enabled
+    || rocker_installed_center_x - rocker_body_size[0] / 2
+        >= wall_thickness + lid_lip_thickness + fit_clearance,
+    "Rocker body overlaps the front lid lip");
+assert(!battery_enabled
+    || rocker_installed_center_x + rocker_body_size[0] / 2
+        <= case_length - wall_thickness - lid_lip_thickness - fit_clearance,
+    "Rocker body overlaps the rear lid lip");
+assert(!battery_enabled
+    || rocker_installed_center_y - rocker_body_size[1] / 2
+        >= wall_thickness + lid_lip_thickness + fit_clearance,
+    "Rocker body overlaps the Feather-side lid lip");
+assert(!battery_enabled || rocker_boss_clearance >= fit_clearance - eps,
+    "Rocker body overlaps a lid boss");
+assert(!battery_enabled
+    || rocker_relief_boss_clearance >= fit_clearance - eps,
+    "Rocker tab relief overlaps a lid boss scallop");
+assert(!battery_enabled
+    || abs(
+        case_width - rocker_lid_center_y - rocker_installed_center_y
+    ) < eps,
+    "Rocker lid cutout does not mirror to the installed switch location");
+assert(!battery_enabled
+    || body_height - rocker_body_size[2] >= effective_floor,
+    "Rocker body intersects the case floor");
 
 function clamp(v, lo, hi) = min(max(v, lo), hi);
 function cutout_height(entry) = len(entry) > 5 ? entry[5] : entry[4];
@@ -297,8 +477,8 @@ module rounded_box(size, radius) {
         rounded_rect_2d([size[0], size[1]], radius);
 }
 
-module insert_pocket(diameter, depth, entry_z, downward = true) {
+module insert_pocket(diameter, entry_diameter, depth, entry_z, downward = true) {
-    bore_d = diameter + hole_compensation;
+    bore_d = diameter;
     if (downward) {
         translate([0, 0, entry_z - depth])
             cylinder(h = depth + eps, d = bore_d);
@@ -306,7 +486,7 @@ module insert_pocket(diameter, depth, entry_z, downward = true) {
             cylinder(
                 h = insert_entry_chamfer + eps,
                 d1 = bore_d,
-                d2 = bore_d + 2 * insert_entry_chamfer
+                d2 = entry_diameter
             );
     } else {
         translate([0, 0, entry_z - eps])
@@ -314,7 +494,7 @@ module insert_pocket(diameter, depth, entry_z, downward = true) {
         translate([0, 0, entry_z - eps])
             cylinder(
                 h = insert_entry_chamfer + eps,
-                d1 = bore_d + 2 * insert_entry_chamfer,
+                d1 = entry_diameter,
                 d2 = bore_d
             );
     }
@@ -457,20 +637,27 @@ module battery_cradle() {
         battery_end_x - 4
     ];
 
-    // Board/battery partition, with a lead-routing notch near the JST end.
+    // One open-topped front passage provides JST plug access and enough room
+    // to route the battery lead beneath the Feather PCB beside the lid boss.
     difference() {
         translate([wall_thickness, partition_y, effective_floor - eps])
             cube([
                 battery_end_x - wall_thickness + battery_end_clearance,
-                wall_thickness,
+                battery_partition_thickness,
                 partition_height - effective_floor + eps
             ]);
         translate([
-            board_origin_x + 6.5,
+            wall_thickness - eps,
             partition_y - eps,
             effective_floor + 1.5
         ])
-            cube([9, wall_thickness + 2 * eps, 6]);
+            cube([
+                board_origin_x + jst_center_xy[0]
+                    + (jst_body_size[0] + 2 * jst_relief_clearance) / 2
+                    - wall_thickness + 2 * eps,
+                battery_partition_thickness + 2 * eps,
+                partition_height - effective_floor - 1.5 + eps
+            ]);
     }
 
     // Three low curved ribs cradle the protected cylindrical pack.
@@ -501,29 +688,16 @@ module battery_cradle() {
         battery_end_x + battery_end_clearance
     ])
         translate([
-            x,
+            x - eps,
             battery_center_y - battery_diameter / 2 - battery_radial_clearance,
             effective_floor - eps
         ])
             cube([
-                wall_thickness,
+                wall_thickness + 2 * eps,
                 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() {
@@ -542,7 +716,7 @@ module body_positive() {
         if (battery_enabled)
             battery_cradle();
         if (tripod_insert_enabled)
-            translate([case_length / 2, case_width / 2, 0])
+            translate([tripod_center_x, tripod_center_y, 0])
                 cylinder(h = effective_floor, d = tripod_boss_diameter);
         if (usb_guide_active)
             usb_guide_shell();
@@ -555,6 +729,7 @@ module body_cutouts() {
         translate([board_origin_x + mx, board_origin_y + my, 0])
             insert_pocket(
                 m25_insert_hole_diameter,
+                m25_insert_outer_diameter,
                 m25_insert_length + insert_melt_relief,
                 board_bottom_z
             );
@@ -564,6 +739,7 @@ module body_cutouts() {
         translate([p[0], p[1], 0])
             insert_pocket(
                 m25_insert_hole_diameter,
+                m25_insert_outer_diameter,
                 m25_insert_length + insert_melt_relief,
                 body_height
             );
@@ -579,29 +755,8 @@ module body_cutouts() {
             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([tripod_center_x, tripod_center_y, 0]) {
             translate([0, 0, -eps])
                 cylinder(
                     h = effective_floor + 2 * eps,
@@ -609,6 +764,7 @@ module body_cutouts() {
                 );
             insert_pocket(
                 tripod_insert_hole_diameter,
+                tripod_insert_outer_diameter,
                 tripod_insert_length + insert_melt_relief,
                 effective_floor
             );
@@ -702,6 +858,13 @@ module oled_button_lid_cutout(xy) {
 module lid_cutouts() {
     // Through holes plus shallow counterbores for flush M2.5 socket heads.
     for (p = lid_boss_xy) {
+        // Scallop only the locating lip so it can pass over the full-height
+        // insert boss while leaving the lid plate supported by the boss top.
+        translate([p[0], p[1], lid_thickness - eps])
+            cylinder(
+                h = lid_lip_depth + 2 * eps,
+                d = m25_boss_diameter + 2 * fit_clearance
+            );
         translate([p[0], p[1], -eps])
             cylinder(
                 h = lid_thickness + lid_lip_depth + 2 * eps,
@@ -714,6 +877,19 @@ module lid_cutouts() {
             );
     }
 
+    if (battery_enabled) {
+        translate([rocker_lid_center_x, rocker_lid_center_y, -eps])
+            centered_rounded_prism(
+                rocker_cutout_size,
+                lid_thickness + lid_lip_depth + 2 * eps,
+                rocker_corner_radius
+            );
+        rocker_tab_reliefs(
+            [rocker_lid_center_x, rocker_lid_center_y],
+            rocker_cutout_size
+        );
+    }
+
     if (top_profile == "oled128x64") {
         beveled_oled_window();
         if (button_a) oled_button_lid_cutout(oled_button_a_xy);
@@ -723,13 +899,90 @@ module lid_cutouts() {
     }
 }
 
-module lid() {
+// Thin the horizontal top/bottom edges of the upright switch opening where the
+// spring tabs latch. Each full-width land overlaps the rounded opening by its
+// corner radius, then extends outward before tapering to the surrounding lid.
+module rocker_tab_reliefs(center, opening_size) {
+    relief_depth = lid_thickness - rocker_tab_panel_thickness;
+    opening_overlap = rocker_corner_radius;
+    strip = 0.02;
+    for (side = [-1, 1]) {
+        edge_y = center[1] + side * opening_size[1] / 2;
+        translate([
+            center[0] - opening_size[0] / 2,
+            edge_y - (side < 0 ? rocker_tab_land : opening_overlap),
+            rocker_tab_panel_thickness
+        ])
+            cube([opening_size[0], rocker_tab_land + opening_overlap,
+                relief_depth + eps]);
+
+        hull() {
+            translate([
+                center[0] - opening_size[0] / 2,
+                edge_y + side * rocker_tab_land - (side < 0 ? strip : 0),
+                rocker_tab_panel_thickness
+            ])
+                cube([opening_size[0], strip, relief_depth + eps]);
+            translate([
+                center[0] - opening_size[0] / 2,
+                edge_y + side * (rocker_tab_land + rocker_tab_taper_length)
+                    - (side < 0 ? strip : 0),
+                lid_thickness - strip
+            ])
+                cube([opening_size[0], strip, strip + eps]);
+        }
+    }
+}
+
+module lid_artwork_nominal_2d() {
+    translate(lid_art_center)
+        rotate(lid_art_rotation)
+            // The lid is modeled exterior-face-down; mirror the artwork so it
+            // reads normally after the lid is turned into service position.
+            mirror([0, 1, 0]) {
+                if (lid_logo_enabled)
+                    translate([0, lid_logo_center_y])
+                        resize(logo_size)
+                            import(logo_file, center = true);
+                if (lid_label != "")
+                    translate([0, lid_label_center_y])
+                        text(
+                            lid_label,
+                            size = lid_label_size,
+                            halign = "center",
+                            valign = "center",
+                            font = "DejaVu Sans:style=Bold"
+                        );
+            }
+}
+
+module lid_artwork_2d(inset = 0) {
+    offset(delta = inset)
+        lid_artwork_nominal_2d();
+}
+
+module lid_base() {
     difference() {
         lid_plate_positive();
         lid_cutouts();
+        if (lid_artwork_enabled)
+            translate([0, 0, -eps])
+                linear_extrude(height = lid_inlay_depth + eps)
+                    lid_artwork_2d(lid_inlay_fit_clearance);
     }
 }
 
+module lid_accent() {
+    if (lid_artwork_enabled)
+        linear_extrude(height = lid_inlay_depth)
+            lid_artwork_2d();
+}
+
+module lid() {
+    color([0.92, 0.92, 0.95]) lid_base();
+    color([0.95, 0.42, 0.08]) lid_accent();
+}
+
 module one_oled_button() {
     recess_depth = button_flange_thickness + button_travel;
     stem_height = lid_thickness - recess_depth + button_projection;
@@ -769,6 +1022,13 @@ 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([0.92, 0.92, 0.86, 0.9])
+        translate([
+            board_origin_x + jst_center_xy[0] - jst_body_size[0] / 2,
+            board_origin_y + jst_center_xy[1] - 4.5,
+            board_top_z
+        ])
+            cube(jst_body_size);
     color([0.12, 0.45, 0.75, 0.45])
         for (i = [1 : wing_count])
             translate([
@@ -835,19 +1095,20 @@ module reference_battery_and_switch() {
             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])
+        color([0.08, 0.08, 0.08, 0.85])
             translate([
-                switch_center_x,
+                rocker_installed_center_x - rocker_body_size[0] / 2,
-                case_width - wall_thickness,
+                rocker_installed_center_y - rocker_body_size[1] / 2,
-                switch_center_z
+                body_height + exploded_view - rocker_body_size[2]
             ])
-                rotate([90, 0, 0]) {
+                cube(rocker_body_size);
-                    cylinder(h = switch_body_length, d = switch_body_diameter);
+        color([0.12, 0.12, 0.12, 0.95])
-                    translate([0, 0, -1.5])
+            translate([
-                        cylinder(h = 1.5, d = switch_flange_diameter);
+                rocker_installed_center_x - rocker_cutout_size[0] / 2,
-                    translate([0, 0, -3])
+                rocker_installed_center_y - rocker_cutout_size[1] / 2,
-                        cylinder(h = 3, d = switch_cap_diameter);
+                body_height + exploded_view + lid_thickness
-                }
+            ])
+                cube([rocker_cutout_size[0], rocker_cutout_size[1], 2.5]);
     }
 }
 
@@ -865,13 +1126,9 @@ module assembly() {
                 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_length = spacing * len(tripod_coupon_steps) + 8;
     coupon_width = 32;
     coupon_height = max(
         m25_insert_length + insert_melt_relief + 1.2,
@@ -879,17 +1136,21 @@ module insert_coupon() {
     );
     difference() {
         rounded_box([coupon_length, coupon_width, coupon_height], 3);
-        for (i = [0 : len(coupon_steps) - 1]) {
+        for (i = [0 : len(tripod_coupon_steps) - 1]) {
             x = 7 + i * spacing;
-            coupon_hole(
+            translate([x, 8, 0])
-                x, 8,
+                insert_pocket(
-                m25_insert_hole_diameter + coupon_steps[i],
+                    m25_insert_hole_diameter + m25_coupon_steps[i],
-                m25_insert_length + insert_melt_relief
+                    m25_insert_outer_diameter,
+                    m25_insert_length + insert_melt_relief,
+                    coupon_height
                 );
-            coupon_hole(
+            translate([x, 23, 0])
-                x, 23,
+                insert_pocket(
-                tripod_insert_hole_diameter + coupon_steps[i],
+                    tripod_insert_hole_diameter + tripod_coupon_steps[i],
-                tripod_insert_length + insert_melt_relief
+                    tripod_insert_outer_diameter,
+                    tripod_insert_length + insert_melt_relief,
+                    coupon_height
                 );
         }
     }
@@ -898,16 +1159,23 @@ module insert_coupon() {
 module switch_coupon() {
     spacing = 18;
     coupon_length = spacing * len(coupon_steps) + 6;
-    coupon_width = 24;
+    coupon_width = rocker_cutout_size[1] + 6;
-    coupon_height = wall_thickness;
+    coupon_height = lid_thickness;
     difference() {
         rounded_box([coupon_length, coupon_width, coupon_height], 3);
-        for (i = [0 : len(coupon_steps) - 1])
+        for (i = [0 : len(coupon_steps) - 1]) {
             translate([6 + i * spacing, coupon_width / 2, -eps])
-                cylinder(
+                centered_rounded_prism(
-                    h = coupon_height + 2 * eps,
+                    rocker_cutout_size
-                    d = switch_hole_diameter + coupon_steps[i]
+                        + [coupon_steps[i], coupon_steps[i]],
+                    coupon_height + 2 * eps,
+                    rocker_corner_radius
                 );
+            rocker_tab_reliefs(
+                [6 + i * spacing, coupon_width / 2],
+                rocker_cutout_size + [coupon_steps[i], coupon_steps[i]]
+            );
+        }
     }
 }
 
@@ -953,6 +1221,10 @@ else if (part == "body")
     body();
 else if (part == "lid")
     lid();
+else if (part == "lid_base")
+    lid_base();
+else if (part == "lid_accent")
+    lid_accent();
 else if (part == "buttons")
     buttons();
 else if (part == "insert_coupon")

lib/feather_case_wizard.rb

@@ -23,4 +23,7 @@ module FeatherCaseWizard
   CASES_ROOT = ROOT.join("cases").freeze
   MODEL_SOURCE = ROOT.join("feather_case.scad").freeze
   RENDERER_SOURCE = ROOT.join("tools/render_stl_previews.py").freeze
+  MULTICOLOR_RENDERER_SOURCE = ROOT.join("tools/render_multicolor_lid.py").freeze
+  MULTICOLOR_PACKAGER_SOURCE = ROOT.join("tools/package_multimaterial_3mf.py").freeze
+  LOGO_SOURCE = ROOT.join("assets/NME-fixed.svg").freeze
 end

lib/feather_case_wizard/config.rb

@@ -10,6 +10,11 @@ module FeatherCaseWizard
     FACES = %w[front rear left right].freeze
     SHAPES = %w[circle rect roundrect slot].freeze
     COUPONS = %w[insert_coupon switch_coupon fit_coupon].freeze
+    LID_ART_ORIENTATIONS = %w[usb_left usb_front usb_right usb_rear].freeze
+    LEGACY_SWITCH_FIELDS = %w[switch_hole_diameter switch_hole_compensation
+                              switch_cap_diameter switch_flange_diameter
+                              switch_body_length switch_body_diameter
+                              switch_wire_allowance].freeze
 
     DEFAULT_PARAMETERS = {
       "top_profile" => "generic",
@@ -38,20 +43,25 @@ module FeatherCaseWizard
       "battery_diameter" => 18.0,
       "battery_radial_clearance" => 0.6,
       "battery_end_clearance" => 1.0,
-      "switch_hole_diameter" => 12.0,
+      "battery_partition_thickness" => 1.8,
-      "switch_hole_compensation" => 0.3,
+      "battery_board_clearance" => 3.0,
-      "switch_cap_diameter" => 8.0,
+      "rocker_cutout_size" => [12.9, 19.4],
-      "switch_flange_diameter" => 16.2,
+      "rocker_corner_radius" => 0.8,
-      "switch_body_length" => 24.0,
+      "rocker_body_size" => [15.0, 21.0, 21.0],
-      "switch_body_diameter" => 12.0,
+      "rocker_artwork_gap" => 2.0,
-      "switch_wire_allowance" => 3.0,
+      "rocker_partition_offset" => 2.0,
+      "rocker_tab_panel_thickness" => 2.0,
+      "rocker_tab_land" => 2.0,
+      "rocker_tab_taper_length" => 0.6,
       "tripod_insert_enabled" => false,
-      "tripod_insert_length" => 6.4,
+      "tripod_insert_length" => 5.0,
-      "tripod_insert_hole_diameter" => 8.8,
+      "tripod_insert_hole_diameter" => 7.2,
+      "tripod_insert_outer_diameter" => 8.0,
       "tripod_thread_clearance_diameter" => 6.8,
       "tripod_boss_diameter" => 14.0,
       "m25_insert_length" => 4.0,
-      "m25_insert_hole_diameter" => 3.7,
+      "m25_insert_hole_diameter" => 3.1,
+      "m25_insert_outer_diameter" => 3.5,
       "m25_screw_clearance" => 2.8,
       "m25_boss_diameter" => 7.0,
       "insert_entry_chamfer" => 0.6,
@@ -76,10 +86,18 @@ module FeatherCaseWizard
       "usb_connector_overhang" => 2.0,
       "usb_guide_wall_thickness" => 1.2,
       "usb_guide_end_gap" => 1.0,
-      "usb_opening_width" => 12.5,
+      "lid_label" => "",
-      "usb_opening_height" => 7.0,
+      "lid_logo_enabled" => false,
+      "lid_art_orientation" => "usb_left",
+      "lid_inlay_depth" => 0.6,
+      "lid_inlay_fit_clearance" => 0.08,
+      "lid_label_size" => 5.0,
+      "lid_label_logo_gap" => 2.0,
+      "lid_art_margin" => 8.5,
+      "usb_opening_width" => 13.5,
+      "usb_opening_height" => 8.0,
       "usb_opening_radius" => 1.5,
-      "usb_vertical_offset" => 0.0
+      "usb_vertical_offset" => 0.5
     }.freeze
 
     ADVANCED_FIELDS = {
@@ -87,19 +105,27 @@ module FeatherCaseWizard
                     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 lid_lip_depth
+                            board_bottom_clearance board_side_clearance board_rear_clearance
-                            lid_lip_thickness fit_clearance cutout_min_web hole_compensation
+                            usb_board_wall_gap lid_lip_depth lid_lip_thickness fit_clearance
-                            lid_screw_head_diameter lid_screw_head_height],
+                            cutout_min_web hole_compensation lid_screw_head_diameter
+                            lid_screw_head_height],
+      "Lid artwork" => %w[lid_inlay_depth lid_inlay_fit_clearance lid_label_size
+                           lid_label_logo_gap lid_art_margin],
       "M2.5 inserts" => %w[m25_insert_length m25_insert_hole_diameter
+                           m25_insert_outer_diameter
                            m25_screw_clearance m25_boss_diameter
                            insert_entry_chamfer insert_melt_relief],
       "Tripod insert" => %w[tripod_insert_length tripod_insert_hole_diameter
+                            tripod_insert_outer_diameter
                             tripod_thread_clearance_diameter tripod_boss_diameter],
       "Battery and switch" => %w[battery_length battery_diameter battery_radial_clearance
-                                 battery_end_clearance switch_hole_diameter
+                                 battery_end_clearance battery_partition_thickness
-                                 switch_hole_compensation switch_cap_diameter
+                                 battery_board_clearance
-                                 switch_flange_diameter switch_body_length
+                                 rocker_cutout_size rocker_corner_radius
-                                 switch_body_diameter switch_wire_allowance],
+                                 rocker_body_size rocker_artwork_gap
+                                 rocker_partition_offset
+                                 rocker_tab_panel_thickness rocker_tab_land
+                                 rocker_tab_taper_length],
       "USB-C opening" => %w[usb_opening_width usb_opening_height
                             usb_opening_radius usb_vertical_offset usb_connector_overhang
                             usb_guide_wall_thickness usb_guide_end_gap],
@@ -158,6 +184,7 @@ module FeatherCaseWizard
 
     def printable_parts
       parts = %w[body lid]
+      parts.concat(%w[lid_base lid_accent]) if lid_artwork?
       if parameters["top_profile"] == "oled128x64" &&
          %w[button_a button_b button_c button_reset].any? { |key| parameters[key] }
         parts << "buttons"
@@ -165,6 +192,10 @@ module FeatherCaseWizard
       parts + outputs["coupons"]
     end
 
+    def lid_artwork?
+      !parameters["lid_label"].empty? || parameters["lid_logo_enabled"]
+    end
+
     def model_parameters
       parameters.merge("extra_cutouts" => scad_cutouts)
     end
@@ -179,7 +210,10 @@ module FeatherCaseWizard
         p["m25_insert_length"] + p["insert_melt_relief"] + 0.6
       ].max
       board_origin_x = p["wall_thickness"] + p["usb_board_wall_gap"]
-      board_origin_y = p["wall_thickness"] + p["board_side_clearance"]
+      combined_tripod_board_gutter = p["battery_enabled"] && p["tripod_insert_enabled"] ?
+        2.4 : 0.0
+      board_origin_y = p["wall_thickness"] + p["board_side_clearance"] +
+                       combined_tripod_board_gutter
       board_top_z = effective_floor + effective_board_clearance + 1.6
       top_pcb_z = board_top_z + (
         p["stack_height_override"].positive? ?
@@ -198,41 +232,41 @@ module FeatherCaseWizard
       plain_width = board_origin_y + 22.86 + p["board_side_clearance"] +
                     p["wall_thickness"]
       if p["battery_enabled"]
-        partition_y = board_origin_y + 22.86 + 1
+        partition_y = board_origin_y + 22.86 + p["battery_board_clearance"]
-        battery_y = partition_y + p["wall_thickness"] +
+        battery_y = partition_y + p["battery_partition_thickness"] +
                     p["battery_radial_clearance"] + p["battery_diameter"] / 2
-        battery_start_x = board_origin_x + p["battery_end_clearance"]
+        lid_boss_wall_overlap = 0.6
+        lid_boss_front_x = p["wall_thickness"] + p["m25_boss_diameter"] / 2 -
+                           lid_boss_wall_overlap
+        battery_start_x = lid_boss_front_x + p["m25_boss_diameter"] / 2 +
+                          p["battery_end_clearance"]
         battery_end_x = battery_start_x + p["battery_length"]
-        switch_x = battery_end_x + [
+        battery_length_required = battery_end_x + p["battery_end_clearance"] +
-          p["switch_body_diameter"] / 2 + 0.8,
+                                  p["wall_thickness"] + p["m25_boss_diameter"] -
-          p["switch_flange_diameter"] / 2 + 0.5
+                                  lid_boss_wall_overlap
-        ].max
+        length = [plain_length, battery_length_required].max
-        length = [plain_length, switch_x + p["switch_flange_diameter"] / 2 +
-                  1.2 + p["wall_thickness"]].max
         width = [plain_width, battery_y + p["battery_diameter"] / 2 +
                  p["battery_radial_clearance"] + p["wall_thickness"]].max
         battery_z = effective_floor + p["battery_radial_clearance"] +
                     p["battery_diameter"] / 2
-        switch_z = [
+        battery_ceiling = battery_z + p["battery_diameter"] / 2 +
-          effective_floor + p["switch_flange_diameter"] / 2 + 1,
+                          p["battery_radial_clearance"]
-          battery_z
+        rocker_ceiling = effective_floor + p["rocker_body_size"][2] +
-        ].max
+                         p["fit_clearance"]
-        battery_ceiling = [
-          battery_z + p["battery_diameter"] / 2 + p["battery_radial_clearance"],
-          switch_z + p["switch_flange_diameter"] / 2 + 1
-        ].max
       else
         length = plain_length
         width = plain_width
         battery_ceiling = 0
+        rocker_ceiling = 0
       end
       {
         "length" => length,
         "width" => width,
-        "height" => [top_pcb_z + component_height + top_gap, battery_ceiling].max,
+        "height" => [top_pcb_z + component_height + top_gap,
+                     battery_ceiling, rocker_ceiling].max,
         "floor" => effective_floor,
-        "lip_bottom" => [top_pcb_z + component_height + top_gap, battery_ceiling].max -
+        "lip_bottom" => [top_pcb_z + component_height + top_gap,
-                        p["lid_lip_depth"]
+                         battery_ceiling, rocker_ceiling].max - p["lid_lip_depth"]
       }
     end
 
@@ -265,6 +299,15 @@ module FeatherCaseWizard
         raise ConfigError, "Slug must contain lowercase letters, numbers, and single hyphens"
       end
       raise ConfigError, "Unsupported top profile" unless PROFILES.include?(parameters["top_profile"])
+      unless LID_ART_ORIENTATIONS.include?(parameters["lid_art_orientation"])
+        raise ConfigError, "Unsupported lid art orientation"
+      end
+      unless parameters["lid_label"].is_a?(String)
+        raise ConfigError, "lid_label must be text"
+      end
+      if lid_artwork? && parameters["top_profile"] == "oled128x64"
+        raise ConfigError, "Lid artwork is not supported with the OLED profile"
+      end
       raise ConfigError, "wing_count must be between 1 and 8" unless (1..8).cover?(parameters["wing_count"])
       raise ConfigError, "At least one export format is required" if outputs["formats"].empty?
       unless (outputs["formats"] - FORMATS).empty?
@@ -289,9 +332,27 @@ module FeatherCaseWizard
         parameters["stack_height_override"].negative?
       raise ConfigError, "wall_thickness must be at least 1.2 mm" if
         parameters["wall_thickness"] < 1.2
+      raise ConfigError, "battery_partition_thickness must be at least 1.2 mm" if
+        parameters["battery_partition_thickness"] < 1.2
+      raise ConfigError, "rocker_tab_panel_thickness must be at least 1.2 mm" if
+        parameters["rocker_tab_panel_thickness"] < 1.2
+      if parameters["rocker_tab_panel_thickness"] >= parameters["lid_thickness"]
+        raise ConfigError, "rocker_tab_panel_thickness must be less than lid_thickness"
+      end
       raise ConfigError, "lid_lip_thickness must be at least 1.2 mm" if
         parameters["lid_lip_thickness"] < 1.2
+      raise ConfigError, "lid_inlay_depth must be less than lid_thickness" if
+        parameters["lid_inlay_depth"] >= parameters["lid_thickness"]
+      if parameters["m25_insert_outer_diameter"] < parameters["m25_insert_hole_diameter"]
+        raise ConfigError, "m25_insert_outer_diameter must not be smaller than the pilot"
+      end
+      if parameters["tripod_insert_outer_diameter"] <
+         parameters["tripod_insert_hole_diameter"]
+        raise ConfigError,
+              "tripod_insert_outer_diameter must not be smaller than the pilot"
+      end
 
+      validate_usb_opening!
       validate_cutouts!
       self
     end
@@ -305,6 +366,7 @@ module FeatherCaseWizard
       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
+      LEGACY_SWITCH_FIELDS.each { |key| data["parameters"].delete(key) }
       data["cutouts"] ||= []
       data["outputs"] ||= {}
       data["outputs"]["formats"] ||= ["3mf"]
@@ -355,6 +417,19 @@ module FeatherCaseWizard
       validate_cutout_spacing!(bounds, dims)
     end
 
+    def validate_usb_opening!
+      return unless parameters["usb_opening_enabled"]
+
+      dims = dimensions
+      bounds = usb_wall_bounds(dims)
+      if bounds["bottom"] < dims["floor"]
+        raise ConfigError, "USB opening or guide intersects the case floor"
+      end
+      if bounds["top"] > dims["lip_bottom"]
+        raise ConfigError, "USB opening or guide intersects the lid lip"
+      end
+    end
+
     def validate_cutout_spacing!(bounds, dims)
       web = parameters["cutout_min_web"]
       bounds.combination(2) do |first, second|

lib/feather_case_wizard/package_builder.rb

@@ -2,16 +2,23 @@
 
 module FeatherCaseWizard
   class PackageBuilder
-    attr_reader :config, :root, :toolchain, :model_source, :renderer_source
+    attr_reader :config, :root, :toolchain, :model_source, :renderer_source,
+                :multicolor_renderer_source, :multicolor_packager_source, :logo_source
 
     def initialize(config, root: CASES_ROOT, toolchain: Toolchain.new,
                    model_source: MODEL_SOURCE, renderer_source: RENDERER_SOURCE,
+                   multicolor_renderer_source: MULTICOLOR_RENDERER_SOURCE,
+                   multicolor_packager_source: MULTICOLOR_PACKAGER_SOURCE,
+                   logo_source: LOGO_SOURCE,
                    reporter: nil)
       @config = config
       @root = Pathname(root)
       @toolchain = toolchain
       @model_source = Pathname(model_source)
       @renderer_source = Pathname(renderer_source)
+      @multicolor_renderer_source = Pathname(multicolor_renderer_source)
+      @multicolor_packager_source = Pathname(multicolor_packager_source)
+      @logo_source = Pathname(logo_source)
       @reporter = reporter || ->(_message) {}
     end
 
@@ -37,13 +44,22 @@ module FeatherCaseWizard
     def verify_sources!
       raise ToolError, "Missing model source: #{model_source}" unless model_source.file?
       raise ToolError, "Missing preview renderer: #{renderer_source}" unless renderer_source.file?
+      raise ToolError, "Missing multicolor renderer: #{multicolor_renderer_source}" unless
+        multicolor_renderer_source.file?
+      raise ToolError, "Missing multicolor packager: #{multicolor_packager_source}" unless
+        multicolor_packager_source.file?
+      raise ToolError, "Missing lid logo: #{logo_source}" unless logo_source.file?
     end
 
     def prepare_package(stage, previous)
       source_dir = stage.join("source")
-      FileUtils.mkdir_p(source_dir)
+      tools_dir = stage.join("tools")
+      FileUtils.mkdir_p([source_dir, source_dir.join("assets"), tools_dir])
       FileUtils.cp(model_source, source_dir.join("feather_case.scad"))
       FileUtils.cp(renderer_source, source_dir.join("render_stl_previews.py"))
+      FileUtils.cp(multicolor_renderer_source, source_dir.join("render_multicolor_lid.py"))
+      FileUtils.cp(multicolor_packager_source, tools_dir.join("package_multimaterial_3mf.py"))
+      FileUtils.cp(logo_source, source_dir.join("assets/NME-fixed.svg"))
       FileUtils.cp(ROOT.join("templates/standalone_build.rb"), stage.join("build.rb"))
 
       copy_history(previous, stage)
@@ -91,9 +107,26 @@ module FeatherCaseWizard
           report("Exporting #{part}.#{format}")
           export_model(stage, directory.join("#{part}.#{format}"), part)
         end
+        package_multicolor_lid(stage, directory) if format == "3mf" && config.lid_artwork?
       end
     end
 
+    def package_multicolor_lid(stage, directory)
+      report("Packaging lid_multicolor.3mf")
+      command = [
+        toolchain.python,
+        stage.join("tools/package_multimaterial_3mf.py").to_s,
+        directory.join("lid_base.3mf").to_s,
+        directory.join("lid_accent.3mf").to_s,
+        directory.join("lid_multicolor.3mf").to_s,
+        "--title", "#{config.name} Lid"
+      ]
+      toolchain.run!(*command)
+      output = directory.join("lid_multicolor.3mf")
+      raise ToolError, "Multicolor packager did not create #{output}" unless
+        output.file? && output.size.positive?
+    end
+
     def generate_previews(stage)
       previews = stage.join("previews")
       scratch = stage.join(".preview-meshes")
@@ -111,9 +144,22 @@ module FeatherCaseWizard
         export_model(stage, mesh, part) unless mesh.file?
         render(stage, mesh, previews, part, ["iso"])
       end
+      render_multicolor_lid(stage, scratch, previews) if config.lid_artwork?
       FileUtils.rm_rf(scratch)
     end
 
+    def render_multicolor_lid(stage, scratch, previews)
+      report("Rendering multicolor lid preview")
+      command = [
+        toolchain.blender, "--background", "-noaudio", "--python",
+        stage.join("source/render_multicolor_lid.py").to_s, "--",
+        scratch.join("lid_base.stl").to_s,
+        scratch.join("lid_accent.stl").to_s,
+        previews.to_s, "lid_multicolor", config.parameters["lid_art_orientation"]
+      ]
+      toolchain.run!(*command, env: {"DISPLAY" => nil, "WAYLAND_DISPLAY" => nil})
+    end
+
     def export_model(stage, output, part, overrides = {})
       model = stage.join("source/feather_case.scad")
       parameters = config.model_parameters.merge(overrides).merge("part" => part)
@@ -139,6 +185,18 @@ module FeatherCaseWizard
     def write_summary(stage)
       dims = config.dimensions
       parts = config.printable_parts.map { |part| "`#{part}`" }.join(", ")
+      artwork = if config.lid_artwork?
+        <<~ARTWORK.chomp
+
+          For a two-color lid, open `exports/3mf/lid_multicolor.3mf` as one
+          multipart object. Assign “Lid base — Filament 1” and “Accent inlays —
+          Filament 2” to the desired filaments. `lid.3mf` is the complete
+          single-color fallback; `lid_base.3mf` and `lid_accent.3mf` are also
+          provided separately.
+        ARTWORK
+      else
+        ""
+      end
       text = <<~MARKDOWN
         # #{config.name}
 
@@ -154,8 +212,8 @@ module FeatherCaseWizard
         - Custom cutouts: #{config.cutouts.length}
 
         Run `ruby build.rb` in this directory to regenerate exports and previews.
-        OpenSCAD and Blender must be installed. Set `OPENSCAD` or `BLENDER` to
+        OpenSCAD, Blender, and Python 3 must be installed. Set `OPENSCAD`,
-        override their executable paths.
+        `BLENDER`, or `PYTHON` to override their executable paths.
 
         To open the saved Customizer values manually:
 
@@ -165,8 +223,9 @@ module FeatherCaseWizard
 
         The 3MF files contain portable geometry only. Choose printer, filament,
         plate, and slicing settings in Bambu Studio.
+        #{artwork}
       MARKDOWN
-      File.write(stage.join("README.md"), text)
+      File.write(stage.join("README.md"), text.rstrip + "\n")
     end
 
     def install_atomically(stage, destination)

lib/feather_case_wizard/toolchain.rb

@@ -4,18 +4,20 @@ module FeatherCaseWizard
   class ToolError < StandardError; end
 
   class Toolchain
-    attr_reader :openscad, :blender
+    attr_reader :openscad, :blender, :python
 
     def initialize(env: ENV)
       @env = env
       @openscad = discover("OPENSCAD", "openscad")
       @blender = discover("BLENDER", "blender")
+      @python = discover("PYTHON", "python3")
     end
 
     def check!
       missing = []
       missing << "OpenSCAD (`sudo apt-get install openscad` or set OPENSCAD)" unless openscad
       missing << "Blender (`sudo apt-get install blender` or set BLENDER)" unless blender
+      missing << "Python 3 (`sudo apt-get install python3` or set PYTHON)" unless python
       return self if missing.empty?
 
       raise ToolError, "Missing required tools:\n  - #{missing.join("\n  - ")}"

lib/feather_case_wizard/wizard.rb

@@ -44,6 +44,7 @@ module FeatherCaseWizard
       choose_stack(config)
       choose_end_clearance(config)
       choose_features(config)
+      choose_lid_artwork(config)
       manage_cutouts(config)
       choose_coupons(config)
       advanced(config) if ui.agree("Adjust advanced dimensions? (y/n) ") do |question|
@@ -143,6 +144,26 @@ module FeatherCaseWizard
       )
     end
 
+    def choose_lid_artwork(config)
+      p = config.parameters
+      label_enabled = agreement("Add a two-color device title to the lid?",
+                                !p["lid_label"].empty?)
+      p["lid_label"] = label_enabled ? text(
+        "Device title", p["lid_label"].empty? ? config.name : p["lid_label"]
+      ) : ""
+      p["lid_logo_enabled"] = agreement("Add the two-color NME logo to the lid?",
+                                         p["lid_logo_enabled"])
+      return unless !p["lid_label"].empty? || p["lid_logo_enabled"]
+
+      current = p["lid_art_orientation"]
+      p["lid_art_orientation"] = ui.choose("USB position when the lid text is upright") do |menu|
+        Config::LID_ART_ORIENTATIONS.each do |orientation|
+          menu.choice(orientation.delete_prefix("usb_").capitalize) { orientation }
+        end
+        menu.default = (Config::LID_ART_ORIENTATIONS.index(current).to_i + 1).to_s
+      end
+    end
+
     def manage_cutouts(config)
       loop do
         ui.say("Custom cable cutouts: #{config.cutouts.empty? ? "none" :

templates/standalone_build.rb

@@ -44,13 +44,18 @@ config = YAML.safe_load_file(ROOT.join("case.yml"), permitted_classes: [],
                              permitted_symbols: [], aliases: false)
 openscad = executable("OPENSCAD", "openscad")
 blender = executable("BLENDER", "blender")
+python = executable("PYTHON", "python3")
 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")
 )
+artwork = !parameters.fetch("lid_label", "").empty? ||
+          parameters.fetch("lid_logo_enabled", false)
+abort "Python 3 not found; install it or set PYTHON" if artwork && !python
 parts = %w[body lid] + config.fetch("outputs").fetch("coupons")
+parts.concat(%w[lid_base lid_accent]) if artwork
 buttons = %w[button_a button_b button_c button_reset]
 if parameters["top_profile"] == "oled128x64" &&
    buttons.any? { |name| parameters[name] }
@@ -80,6 +85,16 @@ begin
       puts "Exporting #{part}.#{format}…"
       export.call(directory.join("#{part}.#{format}"), part)
     end
+    if artwork && format == "3mf"
+      puts "Packaging lid_multicolor.3mf…"
+      run!(
+        python, ROOT.join("tools/package_multimaterial_3mf.py").to_s,
+        directory.join("lid_base.3mf").to_s,
+        directory.join("lid_accent.3mf").to_s,
+        directory.join("lid_multicolor.3mf").to_s,
+        "--title", "#{config.fetch("name")} Lid"
+      )
+    end
   end
 
   assembly = scratch.join("assembly.stl")
@@ -97,6 +112,16 @@ begin
     run!(blender, "--background", "-noaudio", "--python", renderer.to_s, "--",
          mesh.to_s, previews.to_s, part, "iso", env: render_env)
   end
+  if artwork
+    puts "Rendering multicolor lid preview…"
+    run!(
+      blender, "--background", "-noaudio", "--python",
+      ROOT.join("source/render_multicolor_lid.py").to_s, "--",
+      scratch.join("lid_base.stl").to_s,
+      scratch.join("lid_accent.stl").to_s,
+      previews.to_s, "lid_multicolor", parameters["lid_art_orientation"], env: render_env
+    )
+  end
 
   backup = ROOT.join(".build-old-#{Process.pid}")
   FileUtils.mkdir_p(backup)

test/config_test.rb

@@ -72,6 +72,26 @@ class ConfigTest < Minitest::Test
     assert_match(/guide requires/, error.message)
   end
 
+  def test_usb_opening_expands_upward_without_moving_bottom_edge
+    parameters = config.parameters
+    compensation = parameters["hole_compensation"]
+    board_top = config.dimensions["floor"] +
+                parameters["board_bottom_clearance"] + 1.6
+    old_center = board_top + 1.6
+    old_width = 12.5 + compensation
+    old_height = 7.0 + compensation
+    new_center = old_center + parameters["usb_vertical_offset"]
+    new_width = parameters["usb_opening_width"] + compensation
+    new_height = parameters["usb_opening_height"] + compensation
+
+    assert_in_delta 1.0, new_width - old_width, 0.001
+    assert_in_delta old_center - old_height / 2,
+                    new_center - new_height / 2, 0.001
+    assert_in_delta 1.0,
+                    (new_center + new_height / 2) -
+                    (old_center + old_height / 2), 0.001
+  end
+
   def test_end_clearances_expand_case_length
     subject = config
     subject.parameters["usb_board_wall_gap"] = 20.0
@@ -80,6 +100,48 @@ class ConfigTest < Minitest::Test
     assert_in_delta 95.6, subject.dimensions["length"], 0.01
   end
 
+  def test_insert_defaults_match_selected_hardware
+    parameters = config.parameters
+
+    assert_in_delta 4.0, parameters["m25_insert_length"], 0.001
+    assert_in_delta 3.1, parameters["m25_insert_hole_diameter"], 0.001
+    assert_in_delta 3.5, parameters["m25_insert_outer_diameter"], 0.001
+    assert_in_delta 5.0, parameters["tripod_insert_length"], 0.001
+    assert_in_delta 7.2, parameters["tripod_insert_hole_diameter"], 0.001
+    assert_in_delta 8.0, parameters["tripod_insert_outer_diameter"], 0.001
+  end
+
+  def test_tripod_floor_tracks_insert_length
+    subject = config
+    subject.parameters["tripod_insert_enabled"] = true
+
+    assert_in_delta 7.0, subject.dimensions["floor"], 0.001
+  end
+
+  def test_insert_coupon_uses_finished_pilot_ranges
+    source = FeatherCaseWizard::MODEL_SOURCE.read
+
+    assert_includes source,
+                    "m25_coupon_steps = [-0.15, -0.075, 0, 0.075, 0.15];"
+    assert_includes source,
+                    "tripod_coupon_steps = [-0.3, -0.15, 0, 0.15, 0.3];"
+    assert_includes source, "bore_d = diameter;"
+    refute_includes source, "bore_d = diameter + hole_compensation;"
+  end
+
+  def test_lid_rocker_mirrors_to_installed_feather_side
+    source = FeatherCaseWizard::MODEL_SOURCE.read
+
+    assert_includes source,
+                    "rocker_lid_center_y = case_width - rocker_installed_center_y;"
+    assert_includes source,
+                    "translate([rocker_lid_center_x, rocker_lid_center_y, -eps])"
+    assert_includes source,
+                    "rocker_installed_center_y - rocker_body_size[1] / 2"
+    assert_includes source,
+                    "+ rocker_body_size[1] / 2 + rocker_partition_offset;"
+  end
+
   def test_oled_buttons_and_selected_coupons_are_printable
     subject = config
     subject.parameters["top_profile"] = "oled128x64"
@@ -90,6 +152,111 @@ class ConfigTest < Minitest::Test
     assert_equal %w[body lid buttons fit_coupon], subject.printable_parts
   end
 
+  def test_combined_battery_and_tripod_case_adds_partition_clearance
+    subject = config
+    subject.parameters["battery_enabled"] = true
+    subject.parameters["tripod_insert_enabled"] = true
+
+    assert_in_delta 88.6, subject.dimensions["length"], 0.01
+    assert_in_delta 61.06, subject.dimensions["width"], 0.01
+    assert_in_delta 31.25, subject.dimensions["height"], 0.01
+  end
+
+  def test_battery_board_clearance_moves_the_whole_bay_outward
+    subject = config
+    subject.parameters["battery_enabled"] = true
+    original_width = subject.dimensions["width"]
+
+    subject.parameters["battery_board_clearance"] += 2.0
+
+    assert_in_delta 2.0, subject.dimensions["width"] - original_width, 0.001
+  end
+
+  def test_switch_tab_relief_uses_two_mm_lands_in_lid_and_coupon
+    source = FeatherCaseWizard::MODEL_SOURCE.read
+
+    assert_in_delta 2.0, config.parameters["rocker_tab_panel_thickness"], 0.001
+    assert_in_delta 2.0, config.parameters["rocker_tab_land"], 0.001
+    assert_includes source, "module rocker_tab_reliefs(center, opening_size)"
+    assert_equal 2, source.scan(/rocker_tab_reliefs\(/).length - 1
+    assert_includes source,
+                    "edge_y = center[1] + side * opening_size[1] / 2;"
+    assert_includes source,
+                    "opening_overlap = rocker_corner_radius;"
+    assert_includes source,
+                    "cube([opening_size[0], rocker_tab_land + opening_overlap,"
+    refute_includes source,
+                    "edge_x = center[0] + side * opening_size[0] / 2;"
+  end
+
+  def test_switch_moves_two_mm_toward_partition_on_installed_lid
+    assert_in_delta 2.0, config.parameters["rocker_partition_offset"], 0.001
+  end
+
+  def test_switch_tab_panel_must_be_thinner_than_lid
+    subject = config
+    subject.parameters["rocker_tab_panel_thickness"] =
+      subject.parameters["lid_thickness"]
+
+    error = assert_raises(FeatherCaseWizard::ConfigError) { subject.validate! }
+    assert_match(/rocker_tab_panel_thickness/, error.message)
+  end
+
+  def test_legacy_round_switch_fields_migrate_to_rocker_defaults
+    data = config.data
+    data["parameters"]["switch_hole_diameter"] = 12.0
+    data["parameters"]["switch_body_length"] = 24.0
+
+    subject = FeatherCaseWizard::Config.new(data)
+
+    refute subject.parameters.key?("switch_hole_diameter")
+    refute subject.parameters.key?("switch_body_length")
+    assert_equal [12.9, 19.4], subject.parameters["rocker_cutout_size"]
+    assert_equal [15.0, 21.0, 21.0], subject.parameters["rocker_body_size"]
+  end
+
+  def test_battery_partition_requires_three_06_mm_lines
+    subject = config
+    subject.parameters["battery_partition_thickness"] = 1.19
+
+    error = assert_raises(FeatherCaseWizard::ConfigError) { subject.validate! }
+    assert_match(/battery_partition_thickness/, error.message)
+  end
+
+  def test_insert_entry_cannot_be_smaller_than_pilot
+    subject = config
+    subject.parameters["m25_insert_outer_diameter"] = 3.0
+
+    error = assert_raises(FeatherCaseWizard::ConfigError) { subject.validate! }
+    assert_match(/m25_insert_outer_diameter/, error.message)
+  end
+
+  def test_lid_artwork_adds_base_and_accent_parts
+    subject = config
+    subject.parameters["lid_label"] = "GPS"
+    subject.parameters["lid_logo_enabled"] = true
+
+    assert subject.lid_artwork?
+    assert_equal %w[body lid lid_base lid_accent], subject.printable_parts
+  end
+
+  def test_lid_artwork_rejects_oled_profile
+    subject = config
+    subject.parameters["top_profile"] = "oled128x64"
+    subject.parameters["lid_label"] = "OLED"
+
+    error = assert_raises(FeatherCaseWizard::ConfigError) { subject.validate! }
+    assert_match(/not supported with the OLED profile/, error.message)
+  end
+
+  def test_lid_artwork_orientation_is_named
+    subject = config
+    subject.parameters["lid_art_orientation"] = "diagonal"
+
+    error = assert_raises(FeatherCaseWizard::ConfigError) { subject.validate! }
+    assert_match(/orientation/, error.message)
+  end
+
   def test_wall_local_cutouts_map_to_model_coordinates
     subject = config
     length = subject.dimensions["length"]
@@ -138,7 +305,7 @@ class ConfigTest < Minitest::Test
 
   def test_front_cutout_can_clear_usb_reservation
     subject = config
-    subject.data["cutouts"] = [cutout("front", 10.0).merge("z" => 11.0)]
+    subject.data["cutouts"] = [cutout("front", 8.0).merge("z" => 11.0)]
 
     assert_same subject, subject.validate!
   end

test/package_builder_test.rb

@@ -29,6 +29,7 @@ class PackageBuilderTest < Minitest::Test
       %w[iso front back left right top].each do |view|
         assert destination.join("previews/assembly_#{view}.png").file?
       end
+      refute_match(/\n\n\z/, destination.join("README.md").read)
 
       config.parameters["button_reset"] = true
       build(config, root.join("cases"), tools, model, renderer)
@@ -68,6 +69,30 @@ class PackageBuilderTest < Minitest::Test
     end
   end
 
+  def test_builds_aligned_multicolor_lid_package_when_artwork_is_enabled
+    Dir.mktmpdir do |directory|
+      root = Pathname(directory)
+      tools = create_fake_tools(root)
+      model = root.join("model.scad")
+      renderer = root.join("renderer.py")
+      File.write(model, "cube([1,1,1]);\n")
+      File.write(renderer, "# test renderer\n")
+      config = FeatherCaseWizard::Config.create(name: "IMU", slug: "imu")
+      config.parameters["lid_label"] = "IMU"
+      config.parameters["lid_logo_enabled"] = true
+
+      destination = build(config, root.join("cases"), tools, model, renderer)
+
+      %w[lid lid_base lid_accent].each do |part|
+        assert destination.join("exports/3mf/#{part}.3mf").file?
+      end
+      assert destination.join("exports/3mf/lid_multicolor.3mf").file?
+      assert destination.join("source/assets/NME-fixed.svg").file?
+      assert destination.join("tools/package_multimaterial_3mf.py").file?
+      assert destination.join("previews/lid_multicolor_top.png").file?
+    end
+  end
+
   private
 
   def build(config, root, tools, model, renderer)
@@ -93,14 +118,26 @@ class PackageBuilderTest < Minitest::Test
       #!/usr/bin/env ruby
       require "fileutils"
       args = ARGV[(ARGV.index("--") + 1)..]
+      multicolor = ARGV[ARGV.index("--python") + 1].include?("render_multicolor")
+      if multicolor
+        _base, _accent, output, basename = args
+        views = %w[iso top]
+      else
         _mesh, output, basename, selected = args
         views = selected ? selected.split(",") : %w[iso front back left right top]
+      end
       FileUtils.mkdir_p(output)
       views.each { |view| File.binwrite(File.join(output, "\#{basename}_\#{view}.png"), "png") }
     RUBY
-    FileUtils.chmod(0o755, [openscad, blender])
+    python = bin.join("python3")
+    File.write(python, <<~RUBY)
+      #!/usr/bin/env ruby
+      File.binwrite(ARGV[3], "multipart")
+    RUBY
+    FileUtils.chmod(0o755, [openscad, blender, python])
     FeatherCaseWizard::Toolchain.new(
-      env: {"PATH" => bin.to_s, "OPENSCAD" => openscad.to_s, "BLENDER" => blender.to_s}
+      env: {"PATH" => bin.to_s, "OPENSCAD" => openscad.to_s,
+            "BLENDER" => blender.to_s, "PYTHON" => python.to_s}
     )
   end
 end

test/toolchain_test.rb

@@ -9,6 +9,7 @@ class ToolchainTest < Minitest::Test
 
     assert_match(/OpenSCAD/, error.message)
     assert_match(/Blender/, error.message)
+    assert_match(/Python 3/, error.message)
     assert_match(/apt-get/, error.message)
   end
 
@@ -18,13 +19,14 @@ class ToolchainTest < Minitest::Test
       File.write(executable, "#!/bin/sh\nexit 0\n")
       FileUtils.chmod(0o755, executable)
       toolchain = FeatherCaseWizard::Toolchain.new(
-        env: {"PATH" => "", "OPENSCAD" => executable, "BLENDER" => executable}
+        env: {"PATH" => "", "OPENSCAD" => executable, "BLENDER" => executable,
+              "PYTHON" => executable}
       )
 
       assert_equal executable, toolchain.openscad
       assert_equal executable, toolchain.blender
+      assert_equal executable, toolchain.python
       assert_same toolchain, toolchain.check!
     end
   end
 end
-

test/wizard_test.rb

@@ -6,8 +6,8 @@ require_relative "test_helper"
 class WizardTest < Minitest::Test
   def test_minimal_new_case_flow_and_confirmation
     input = StringIO.new(
-      ["Demo Case", "", "1", "1", "", "n", "n", "", "", "n", "n", "1",
+      ["Demo Case", "", "1", "1", "", "n", "n", "", "", "n", "n", "n", "n",
-       "n", "n", "n", "n", "y"].join("\n") + "\n"
+       "1", "n", "n", "n", "n", "y"].join("\n") + "\n"
     )
     output = StringIO.new
     wizard = FeatherCaseWizard::Wizard.new(ui: HighLine.new(input, output))
@@ -24,8 +24,8 @@ class WizardTest < Minitest::Test
     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", "n", "", "", "n", "n", "n", "n", "1", "n",
-       "n"].join("\n") + "\n"
+       "n", "n", "n"].join("\n") + "\n"
     )
     wizard = FeatherCaseWizard::Wizard.new(ui: HighLine.new(input, StringIO.new))
 

tools/package_multimaterial_3mf.py

@@ -0,0 +1,138 @@
+#!/usr/bin/env python3
+"""Combine aligned lid meshes into one slicer-friendly multipart 3MF."""
+
+from __future__ import annotations
+
+import argparse
+import copy
+import zipfile
+from pathlib import Path
+from xml.etree import ElementTree as ET
+
+
+CORE = "http://schemas.microsoft.com/3dmanufacturing/core/2015/02"
+ET.register_namespace("", CORE)
+
+CONTENT_TYPES_XML = b'''<?xml version="1.0" encoding="UTF-8"?>
+<Types xmlns="http://schemas.openxmlformats.org/package/2006/content-types">
+  <Default Extension="rels" ContentType="application/vnd.openxmlformats-package.relationships+xml"/>
+  <Default Extension="model" ContentType="application/vnd.ms-package.3dmanufacturing-3dmodel+xml"/>
+</Types>
+'''
+
+RELATIONSHIPS_XML = b'''<?xml version="1.0" encoding="UTF-8"?>
+<Relationships xmlns="http://schemas.openxmlformats.org/package/2006/relationships">
+  <Relationship Target="/3D/3dmodel.model" Id="rel0" Type="http://schemas.microsoft.com/3dmanufacturing/2013/01/3dmodel"/>
+</Relationships>
+'''
+
+
+def load_mesh(path: Path) -> ET.Element:
+    with zipfile.ZipFile(path) as archive:
+        root = ET.fromstring(archive.read("3D/3dmodel.model"))
+    mesh = root.find(f".//{{{CORE}}}mesh")
+    if mesh is None:
+        raise ValueError(f"{path} does not contain a 3MF mesh")
+    return copy.deepcopy(mesh)
+
+
+def model_xml(base: Path, accent: Path, title: str) -> bytes:
+    root = ET.Element(
+        f"{{{CORE}}}model",
+        {
+            "unit": "millimeter",
+            "{http://www.w3.org/XML/1998/namespace}lang": "en-US",
+        },
+    )
+    ET.SubElement(root, f"{{{CORE}}}metadata", {"name": "Title"}).text = title
+    ET.SubElement(root, f"{{{CORE}}}metadata", {"name": "Generator"}).text = (
+        "feather-case-wizard"
+    )
+    resources = ET.SubElement(root, f"{{{CORE}}}resources")
+    materials = ET.SubElement(resources, f"{{{CORE}}}basematerials", {"id": "1"})
+    ET.SubElement(
+        materials, f"{{{CORE}}}base", {"name": "Lid base", "displaycolor": "#D1D5DB"}
+    )
+    ET.SubElement(
+        materials,
+        f"{{{CORE}}}base",
+        {"name": "Accent inlays", "displaycolor": "#F97316"},
+    )
+
+    for object_id, name, source in (
+        (2, "Lid base — Filament 1", base),
+        (3, "Accent inlays — Filament 2", accent),
+    ):
+        obj = ET.SubElement(
+            resources,
+            f"{{{CORE}}}object",
+            {
+                "id": str(object_id),
+                "name": name,
+                "type": "model",
+                "pid": "1",
+                "pindex": str(object_id - 2),
+            },
+        )
+        obj.append(load_mesh(source))
+
+    assembly = ET.SubElement(
+        resources, f"{{{CORE}}}object", {"id": "4", "name": title, "type": "model"}
+    )
+    components = ET.SubElement(assembly, f"{{{CORE}}}components")
+    ET.SubElement(components, f"{{{CORE}}}component", {"objectid": "2"})
+    ET.SubElement(components, f"{{{CORE}}}component", {"objectid": "3"})
+    build = ET.SubElement(root, f"{{{CORE}}}build")
+    ET.SubElement(build, f"{{{CORE}}}item", {"objectid": "4"})
+    return ET.tostring(root, encoding="utf-8", xml_declaration=True)
+
+
+def bambu_model_settings_xml(title: str) -> bytes:
+    root = ET.Element("config")
+    obj = ET.SubElement(root, "object", {"id": "4"})
+    ET.SubElement(obj, "metadata", {"key": "name", "value": title})
+    for part_id, name, extruder in (
+        (2, "Lid base — Filament 1", 1),
+        (3, "Accent inlays — Filament 2", 2),
+    ):
+        part = ET.SubElement(obj, "part", {"id": str(part_id), "subtype": "normal_part"})
+        ET.SubElement(part, "metadata", {"key": "name", "value": name})
+        ET.SubElement(part, "metadata", {"key": "extruder", "value": str(extruder)})
+    ET.SubElement(root, "assemble")
+    return ET.tostring(root, encoding="utf-8", xml_declaration=True)
+
+
+def write_entry(archive: zipfile.ZipFile, name: str, data: bytes) -> None:
+    info = zipfile.ZipInfo(name)
+    info.create_system = 3
+    info.external_attr = 0o100644 << 16
+    info.compress_type = zipfile.ZIP_DEFLATED
+    archive.writestr(info, data)
+
+
+def main() -> None:
+    parser = argparse.ArgumentParser()
+    parser.add_argument("base", type=Path)
+    parser.add_argument("accent", type=Path)
+    parser.add_argument("output", type=Path)
+    parser.add_argument("--title", required=True)
+    args = parser.parse_args()
+
+    args.output.parent.mkdir(parents=True, exist_ok=True)
+    with zipfile.ZipFile(args.output, "w", zipfile.ZIP_DEFLATED) as archive:
+        write_entry(archive, "[Content_Types].xml", CONTENT_TYPES_XML)
+        write_entry(archive, "_rels/.rels", RELATIONSHIPS_XML)
+        write_entry(
+            archive,
+            "3D/3dmodel.model",
+            model_xml(args.base, args.accent, args.title),
+        )
+        write_entry(
+            archive,
+            "Metadata/model_settings.config",
+            bambu_model_settings_xml(args.title),
+        )
+
+
+if __name__ == "__main__":
+    main()

tools/render_multicolor_lid.py

@@ -0,0 +1,101 @@
+"""Render aligned lid-base and accent STLs with distinct materials."""
+
+import os
+import sys
+import math
+
+import bpy
+from mathutils import Matrix, Vector
+
+
+def import_mesh(path, name, color):
+    bpy.ops.wm.stl_import(filepath=os.path.abspath(path))
+    model = bpy.context.selected_objects[0]
+    model.name = name
+    material = bpy.data.materials.new(f"{name} material")
+    material.diffuse_color = color
+    material.metallic = 0.0
+    material.roughness = 0.45
+    model.data.materials.append(material)
+    return model
+
+
+def look_at(camera, target):
+    direction = Vector(target) - camera.location
+    camera.rotation_euler = direction.to_track_quat("-Z", "Y").to_euler()
+
+
+def main():
+    args = sys.argv[sys.argv.index("--") + 1 :]
+    if len(args) not in (4, 5):
+        raise SystemExit(
+            "expected: lid-base.stl lid-accent.stl output-directory basename [orientation]"
+        )
+    base_path, accent_path, output_dir, basename = args[:4]
+    orientation = args[4] if len(args) == 5 else "usb_left"
+    angles = {"usb_left": 0, "usb_front": 90, "usb_right": 180, "usb_rear": 270}
+    if orientation not in angles:
+        raise SystemExit(f"unknown lid orientation: {orientation}")
+    os.makedirs(output_dir, exist_ok=True)
+    bpy.ops.wm.read_factory_settings(use_empty=True)
+    models = [
+        import_mesh(base_path, "Lid base", (0.16, 0.42, 0.72, 1.0)),
+        import_mesh(accent_path, "Accent inlays", (0.95, 0.42, 0.08, 1.0)),
+    ]
+    # Lid exports are print-oriented with the decorated exterior face down.
+    # Turn both aligned parts over and present the configured USB edge in its
+    # named position so previews inspect the finished face as the user will.
+    for model in models:
+        model.matrix_world = (
+            Matrix.Rotation(math.radians(angles[orientation]), 4, "Z")
+            @ Matrix.Rotation(math.pi, 4, "X")
+        )
+    bpy.context.view_layer.update()
+
+    corners = [obj.matrix_world @ Vector(corner) for obj in models for corner in obj.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
+    camera.data.type = "ORTHO"
+    camera.data.ortho_scale = span * 1.35
+
+    key_data = bpy.data.lights.new("Key", type="AREA")
+    key_data.energy = 900
+    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)
+
+    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.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"
+
+    for view, direction in {"iso": (1, -1, 0.8), "top": (0, 0, 1)}.items():
+        camera.location = center + Vector(direction).normalized() * span * 2.2
+        look_at(camera, center)
+        scene.render.filepath = os.path.join(output_dir, f"{basename}_{view}.png")
+        bpy.ops.render.render(write_still=True)
+
+
+if __name__ == "__main__":
+    main()