pre-bemis
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Marcelo
300
rpi-case/rpi5_industrial_case_002.scad
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rpi-case/rpi5_industrial_case_002.scad
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// ============================================================
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// RPi5 Industrial Enclosure — Luckfox DHX-10.1" Touchscreen
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// Version: 002
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// Fixes vs 001:
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// 1. Pedestal foot now projects from REAR FACE in -Z direction
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// 2. Tilt wedge orientation corrected (leans screen back, not forward)
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// 3. Cable glands moved to rear panel face (foot owns the bottom edge)
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// 4. GPIO cutout repositioned to match Pi board top-edge location
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// 5. Port cutout Z-depths corrected using pi_enc_cx/cy consistently
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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 rear M2.5 mount pattern X (mm) ← verify
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scr_mount_y = 75; // screen rear 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: screen rear → Pi board (mm)
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pi_offset_x = 0; // Pi centre horizontal offset from screen centre (mm)
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pi_offset_y = 5; // Pi centre vertical offset upward from screen centre (mm)
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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; // bezel ↔ rear cover fit clearance (mm)
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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 spacing edge-to-edge (mm)
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soc_vent_sz = 30; // SoC direct-vent zone size (mm, square)
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// ── CABLE GLAND PARAMETERS ───────────────────────────────────
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gland_count = 2; // number of M16 cable glands
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gland_dia = 16.5; // M16 clearance hole diameter (mm)
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gland_spacing= 40; // centre-to-centre spacing (mm)
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// ── PEDESTAL PARAMETERS ──────────────────────────────────────
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// ped_tilt = angle of screen from horizontal (deg).
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// 75° from horizontal = 15° lean-back from vertical (near-upright monitor stance).
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// The foot is a wedge that, when flat on a desk, holds the rear cover at
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// (90 - ped_tilt)° from vertical.
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ped_tilt = 75; // screen angle from horizontal (deg)
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ped_depth = 80; // foot plate depth front-to-back (mm)
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ped_width = 200; // foot plate width (mm)
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ped_thick = 6; // foot plate thickness (mm)
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// ── ASSEMBLY PARAMETERS ──────────────────────────────────────
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m3_dia = 3.4; // M3 clearance hole diameter (mm)
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insert_dia = 4.2; // M3 heat-set insert OD (mm)
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insert_h = 6; // heat-set insert depth (mm)
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// ── DERIVED DIMENSIONS (do not edit) ─────────────────────────
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rear_d = pi_standoff + pi_d + 10; // rear cavity depth (10 mm cable headroom)
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enc_w = scr_w + 2*wall; // enclosure outer width
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enc_h = scr_h + 2*wall; // enclosure outer height
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enc_d = rear_d + wall; // rear cover total depth
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// Pi centre in enclosure coordinates (enclosure origin = rear-cover corner)
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pi_enc_cx = wall + scr_w/2 + pi_offset_x; // = 120.5 with defaults
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pi_enc_cy = wall + scr_h/2 + pi_offset_y; // = 79.5 with defaults
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// Z position of Pi board surface (measured from rear of rear cover)
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pi_z = wall + pi_standoff; // = 7.5 with defaults
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// Foot wedge geometry
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// foot_drop: how far the far tip drops below Y=0 so the bottom surface
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// becomes horizontal when the unit stands at ped_tilt from horizontal.
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foot_drop = ped_depth * tan(90 - ped_tilt); // ≈ 21.4 mm for ped_tilt=75
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$fn = 48;
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// ============================================================
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// PRIMITIVES
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// ============================================================
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// Chamfered box — chamfer on all 12 edges via hull of 3 axis-aligned cubes
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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-end vent slot, length along Y, centred at origin
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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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// Row of n vent slots along X
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module vent_row(n, len, w, spacing, depth) {
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for(i=[0:n-1])
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translate([i*(w+spacing), 0, 0])
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slot(len, w, depth);
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}
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// Heat-set insert boss (M3)
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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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// ============================================================
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// PEDESTAL FOOT (integral with rear cover, no supports needed)
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// ============================================================
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// Geometry in model space (rear cover lying on its back, rear face = Z=0):
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// • Foot extends in the -Z direction from Z=0 (behind the rear face)
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// • Top surface is flush with the enclosure bottom at Y=0
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// • Bottom surface is angled: at Z=0 it is ped_thick below Y=0;
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// at Z=-ped_depth it is (ped_thick + foot_drop) below Y=0.
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// • When the unit stands on the desk the angled surface lies flat and the
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// screen tilts back (90-ped_tilt)° from vertical.
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// • Print orientation: rear cover face-down (foot on bed), zero supports.
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module pedestal_foot() {
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foot_x0 = (enc_w - ped_width) / 2;
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translate([foot_x0, 0, 0]) {
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// Main wedge plate
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hull() {
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translate([0, -ped_thick, 0 ])
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cube([ped_width, ped_thick, wall ]);
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translate([0, -(ped_thick+foot_drop), -ped_depth])
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cube([ped_width, ped_thick+foot_drop, wall ]);
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}
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// Left and right stiffening ribs
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for(bx = [0, ped_width - ped_thick]) {
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hull() {
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translate([bx, -ped_thick, 0 ])
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cube([ped_thick, ped_thick, wall ]);
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translate([bx, -(ped_thick+foot_drop), -ped_depth])
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cube([ped_thick, ped_thick+foot_drop, wall ]);
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// Toe point keeps underside triangular (no saggy bridge)
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translate([bx, -ped_thick, -ped_depth])
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cube([ped_thick, ped_thick, wall ]);
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}
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}
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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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cbox(enc_w, enc_h, wall + recess);
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// Active display window (full cut-through)
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translate([(enc_w-scr_active_w)/2, (enc_h-scr_active_h)/2, -0.1])
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cube([scr_active_w, scr_active_h, wall+recess+0.2]);
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// Recess pocket so bezel lip sits 1 mm over screen edge
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translate([(enc_w-scr_w)/2, (enc_h-scr_h)/2, wall])
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cube([scr_w, scr_h, recess+0.1]);
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// M3 corner screw holes (4×)
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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]) 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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n_vent = 6;
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vent_block_w = n_vent*(vent_w+vent_sp) - vent_sp; // total width of vent array
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difference() {
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union() {
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cbox(enc_w, enc_h, enc_d);
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pedestal_foot();
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// M3 insert bosses at 4 corners (inner face)
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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]) insert_boss();
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}
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// ── HOLLOW INTERIOR ───────────────────────────────────
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translate([wall, wall, wall]) cube([scr_w, scr_h, enc_d]);
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// ── LEFT WALL: USB-C power + HDMI ×2 ─────────────────
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// These are on the Pi's left short-edge (56 mm face), facing X=0.
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// Cutout Y-centre is set near the Pi's lower half.
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// Z positions follow port heights above PCB surface.
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// (Short ribbon extensions needed to reach the wall at X=0.)
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//
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// USB-C power
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translate([-0.1,
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pi_enc_cy - pi_h/2 + 3,
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pi_z + 2])
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cube([wall+0.2, 11, 11]);
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// HDMI 0
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translate([-0.1,
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pi_enc_cy - pi_h/2 + 16,
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pi_z + 2])
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cube([wall+0.2, 17, 9]);
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// HDMI 1
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translate([-0.1,
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pi_enc_cy - pi_h/2 + 35,
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pi_z + 2])
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cube([wall+0.2, 17, 9]);
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// ── RIGHT WALL: RJ45 + USB-A ×4 ──────────────────────
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// RJ45 (top of Pi right edge in board orientation)
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translate([enc_w-wall-0.1,
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pi_enc_cy + pi_h/2 - 24,
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pi_z + 1])
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cube([wall+0.2, 22, 16]);
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// USB-A ×4 (two stacked pairs, below RJ45 on right edge)
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translate([enc_w-wall-0.1,
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pi_enc_cy - pi_h/2 + 2,
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pi_z + 1])
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cube([wall+0.2, 50, 15]);
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// ── TOP WALL: GPIO header (40-pin) ────────────────────
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// GPIO is on the Pi's top long edge (85 mm edge at Y = pi_enc_cy + pi_h/2).
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// Cutout aligns with the header strip X-extent (51 mm) centred on Pi.
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// Z-extent: board surface + header height (~11 mm).
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translate([pi_enc_cx - 26,
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pi_enc_cy + pi_h/2 - 0.1,
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pi_z])
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cube([52, wall+0.2, 11]);
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// ── USB-C TOUCH: screen side edge (left, near screen depth) ───
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translate([-0.1,
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enc_h/2 - 6,
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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 (6 × 3×20 mm, 4 mm spacing)
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translate([enc_w/2 - vent_block_w/2,
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-0.1,
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wall + 8])
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rotate([-90, 0, 0])
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vent_row(n_vent, vent_l, vent_w, vent_sp, wall+0.2);
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// Top exhaust slots
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translate([enc_w/2 - vent_block_w/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(n_vent, vent_l, vent_w, vent_sp, wall+0.2);
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// SoC direct-vent array on rear panel, centred over Pi SoC
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translate([pi_enc_cx - soc_vent_sz/2,
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pi_enc_cy - soc_vent_sz/2,
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enc_d - wall - 0.1]) {
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n_soc = floor(soc_vent_sz / (vent_w + vent_sp));
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for(i = [0:n_soc-1])
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translate([i*(vent_w+vent_sp),
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soc_vent_sz/2 - vent_l/2,
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0])
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slot(vent_l, vent_w, wall+0.2);
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}
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// ── CABLE GLANDS: rear panel face, bottom area ────────
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// Two M16 glands through the rear face (Z=0 plane).
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// Positioned below the Pi, above the foot junction.
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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,
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wall + gland_dia/2 + 4,
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-0.1])
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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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// RENDER — exploded assembly (front bezel floats above rear cover)
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// ============================================================
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color("DarkSlateGray", 0.9)
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translate([0, 0, enc_d + 10])
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front_bezel();
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color("SlateGray", 0.85)
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rear_cover();
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