pre-bemis
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Marcelo
289
rpi-case/rpi5_industrial_case_001.scad
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289
rpi-case/rpi5_industrial_case_001.scad
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// ============================================================
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// RPi5 Industrial Enclosure for Luckfox DHX-10.1" Touchscreen
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// Version: 001
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// ============================================================
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// ── SCREEN PARAMETERS ───────────────────────────────────────
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scr_w = 236; // screen outer width (mm)
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scr_h = 144; // screen outer height (mm)
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scr_d = 19; // screen outer depth (mm)
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scr_active_w = 222; // active area width (mm) ← confirm
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scr_active_h = 130; // active area height (mm) ← confirm
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scr_mount_x = 75; // screen M2.5 mount pattern X (mm) ← verify
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scr_mount_y = 75; // screen M2.5 mount pattern Y (mm) ← verify
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// ── RASPBERRY PI 5 PARAMETERS ────────────────────────────────
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pi_w = 85; // Pi board width (mm)
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pi_h = 56; // Pi board height (mm)
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pi_d = 17; // Pi board depth incl. tallest component (mm)
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pi_mnt_x = 58; // Pi mount hole pattern X (mm)
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pi_mnt_y = 49; // Pi mount hole pattern Y (mm)
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pi_standoff = 5; // standoff height between screen rear and Pi (mm)
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// Pi offset from screen center (positive = up, right)
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pi_offset_x = 0; // horizontal offset of Pi center from screen center
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pi_offset_y = 5; // vertical offset upward from screen center
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// ── ENCLOSURE PARAMETERS ─────────────────────────────────────
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wall = 2.5; // wall thickness (mm)
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chamfer = 1.5; // external edge chamfer (mm)
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recess = 1.0; // screen recess depth in front bezel (mm)
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gap = 0.3; // fit clearance between bezel and rear cover
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// ── VENT PARAMETERS ──────────────────────────────────────────
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vent_w = 3; // vent slot width (mm)
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vent_l = 20; // vent slot length (mm)
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vent_sp = 4; // slot pitch (edge to edge) (mm)
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soc_vent_sz = 30; // SoC vent zone size (mm sq)
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// ── CABLE GLAND PARAMETERS ───────────────────────────────────
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gland_count = 2; // number of cable glands
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gland_dia = 16.5; // M16 clearance hole diameter (mm)
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gland_spacing = 40; // spacing between gland centers (mm)
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// ── PEDESTAL PARAMETERS ──────────────────────────────────────
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ped_tilt = 75; // tilt angle from vertical (deg) — screen tilts back
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ped_depth = 80; // foot depth front-to-back (mm)
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ped_width = 200; // foot width (mm)
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ped_thick = 6; // foot plate thickness (mm)
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ped_brace_h = 30; // height of triangular brace
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// ── ASSEMBLY PARAMETERS ──────────────────────────────────────
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m3_dia = 3.4; // M3 clearance hole
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insert_dia = 4.2; // M3 heat-set insert OD
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insert_h = 6; // heat-set insert depth
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// ── DERIVED DIMENSIONS ───────────────────────────────────────
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// Total rear cavity depth = standoffs + Pi + cable headroom
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rear_d = pi_standoff + pi_d + 10; // 10 mm cable headroom
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// Outer enclosure size
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enc_w = scr_w + 2*wall;
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enc_h = scr_h + 2*wall;
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enc_d = rear_d + wall; // rear cover depth
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// Pi center position relative to screen center
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pi_cx = scr_w/2 + pi_offset_x;
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pi_cy = scr_h/2 + pi_offset_y;
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$fn = 48;
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// ============================================================
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// MODULES
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// ============================================================
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// Chamfered box (external chamfer via intersection with offset cube)
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module cbox(w, h, d, c=chamfer) {
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hull() {
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translate([c,c,0]) cube([w-2*c, h-2*c, d]);
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translate([0,c,c]) cube([w, h-2*c, d-2*c]);
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translate([c,0,c]) cube([w-2*c, h, d-2*c]);
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}
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}
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// Rounded slot (for vents)
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module slot(len, w, d) {
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r = w/2;
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hull() {
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translate([0, -len/2+r, 0]) cylinder(r=r, h=d);
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translate([0, len/2-r, 0]) cylinder(r=r, h=d);
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}
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}
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// M2.5 mounting hole
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module m25_hole(d=10) {
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cylinder(d=2.7, h=d);
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}
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// Heat-set insert boss + M3 hole
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module insert_boss(h=insert_h+4) {
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difference() {
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cylinder(d=insert_dia+3, h=h);
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cylinder(d=insert_dia, h=insert_h);
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translate([0,0,insert_h]) cylinder(d=m3_dia, h=h);
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}
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}
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// Single vent slot row (horizontal slots)
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module vent_row(count, slot_len, slot_w, pitch, depth) {
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for(i=[0:count-1]) {
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translate([i*(slot_w+pitch), 0, 0])
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slot(slot_len, slot_w, depth+0.1);
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}
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}
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// ============================================================
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// FRONT BEZEL
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// ============================================================
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module front_bezel() {
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difference() {
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// Outer chamfered shell
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cbox(enc_w, enc_h, wall + recess);
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// Active display window (recessed by 1 mm, then open)
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translate([(enc_w - scr_active_w)/2,
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(enc_h - scr_active_h)/2,
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-0.1])
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cube([scr_active_w, scr_active_h, wall + recess + 0.2]);
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// Bezel lip sits 1 mm over screen edge — recess pocket
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translate([(enc_w - scr_w)/2,
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(enc_h - scr_h)/2,
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wall])
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cube([scr_w, scr_h, recess + 0.1]);
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// Corner M3 screw holes (through bezel flange, 4 corners)
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for(x=[wall+6, enc_w-wall-6])
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for(y=[wall+6, enc_h-wall-6])
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translate([x, y, -0.1])
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cylinder(d=m3_dia, h=wall+recess+0.2);
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}
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}
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// ============================================================
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// REAR COVER
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// ============================================================
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module rear_cover() {
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difference() {
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union() {
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// Main body
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cbox(enc_w, enc_h, enc_d);
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// Pedestal foot (integral)
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pedestal_foot();
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// Heat-set insert bosses at 4 corners (inside)
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for(x=[wall+6, enc_w-wall-6])
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for(y=[wall+6, enc_h-wall-6])
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translate([x, y, enc_d])
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rotate([180,0,0])
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insert_boss();
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}
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// Hollow interior
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translate([wall, wall, wall])
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cube([scr_w, scr_h, enc_d]);
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// ── PORT CUTOUTS ──────────────────────────────────────
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// USB-C power + 2× HDMI on LEFT edge (Pi left side)
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// Pi left edge X position in enclosure coords
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pi_left_x = pi_cx - pi_w/2 + wall;
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// USB-C power (Pi left edge, near bottom of Pi)
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translate([-0.1,
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pi_cy - 8 + wall,
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wall + pi_standoff + 2])
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cube([wall+0.2, 10, 10]);
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// HDMI #1
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translate([-0.1,
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pi_cx - pi_w/2 + wall + 15,
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wall + pi_standoff + 2])
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cube([wall+0.2, 16, 8]);
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// HDMI #2
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translate([-0.1,
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pi_cx - pi_w/2 + wall + 34,
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wall + pi_standoff + 2])
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cube([wall+0.2, 16, 8]);
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// Ethernet RJ45 on RIGHT edge
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translate([enc_w - wall - 0.1,
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pi_cy + pi_h/2 - 22 + wall,
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wall + pi_standoff + 1])
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cube([wall+0.2, 22, 16]);
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// USB-A ×4 on RIGHT edge
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translate([enc_w - wall - 0.1,
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pi_cy - pi_h/2 + wall + 2,
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wall + pi_standoff + 1])
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cube([wall+0.2, 50, 14]);
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// GPIO header on TOP edge
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translate([pi_cx - 30 + wall,
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enc_h - wall - 0.1,
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wall + pi_standoff])
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cube([52, wall+0.2, 12]);
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// USB-C touch on left side edge of SCREEN (not Pi)
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translate([-0.1, enc_h/2 - 6, wall + scr_d - 5])
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cube([wall+0.2, 12, 8]);
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// ── COOLING VENTS ──────────────────────────────────────
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// Bottom intake slots
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translate([enc_w/2 - (5*(vent_w+vent_sp))/2, -0.1, wall+8])
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rotate([-90, 0, 0])
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vent_row(5, vent_l, vent_w, vent_sp, wall+0.2);
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// Top exhaust slots
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translate([enc_w/2 - (5*(vent_w+vent_sp))/2,
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enc_h - wall + 0.1,
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wall+8])
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rotate([90, 0, 0])
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vent_row(5, vent_l, vent_w, vent_sp, wall+0.2);
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// SoC direct vent (rear panel, over Pi SoC area)
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// SoC assumed ~center of Pi board
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translate([pi_cx - soc_vent_sz/2 + wall,
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pi_cy - soc_vent_sz/2 + wall,
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enc_d - wall - 0.1]) {
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count_soc = floor(soc_vent_sz / (vent_w + vent_sp));
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for(i=[0:count_soc-1])
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translate([i*(vent_w+vent_sp), soc_vent_sz/2-vent_l/2, 0])
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slot(vent_l, vent_w, wall+0.2);
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}
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// ── CABLE GLANDS ──────────────────────────────────────
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for(i=[0:gland_count-1]) {
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cx = enc_w/2 + (i - (gland_count-1)/2) * gland_spacing;
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translate([cx, -0.1, wall + gland_dia/2 + 4])
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rotate([-90,0,0])
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cylinder(d=gland_dia, h=wall+0.2);
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}
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}
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}
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// ============================================================
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// PEDESTAL FOOT (integral with rear cover)
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// ============================================================
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module pedestal_foot() {
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// The foot projects from the bottom of the rear cover.
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// It's a wedge that creates the tilt angle.
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// When the assembly stands on the foot, the screen tilts back ped_tilt°.
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//
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// tilt_angle from vertical → wedge front height > back height.
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// foot_front_h = ped_depth * tan(90-ped_tilt)
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foot_front_h = ped_depth * tan(90 - ped_tilt);
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foot_x0 = (enc_w - ped_width) / 2;
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translate([foot_x0, 0, 0]) {
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// Wedge base plate
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hull() {
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// Front edge (taller)
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translate([0, -ped_depth, 0])
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cube([ped_width, 0.1, foot_front_h + ped_thick]);
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// Back edge (at enc base, flush)
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translate([0, 0, 0])
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cube([ped_width, 0.1, ped_thick]);
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}
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// Triangular side braces for rigidity
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for(bx=[0, ped_width-ped_thick]) {
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translate([bx, -ped_depth, 0])
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linear_extrude(ped_thick)
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polygon([[0,0],
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[ped_depth, 0],
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[ped_depth, foot_front_h]]);
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}
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}
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}
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// ============================================================
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// RENDER — exploded assembly view
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// ============================================================
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// Front bezel at Z=0 (face down for printing, shown face up)
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color("DarkSlateGray", 0.9)
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translate([0, 0, enc_d + 5])
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front_bezel();
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// Rear cover
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color("SlateGray", 0.9)
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rear_cover();
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