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Marcelo
2026-04-22 05:04:19 +00:00
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// ============================================================
// RPi5 Industrial Enclosure — Luckfox DHX-10.1" Touchscreen
// Version: 003
// Fixes vs 002:
// 1. Kickstand completely redesigned — shorter, thinner, clearly
// attached to rear cover bottom, triangular gussets on each side
// 2. GPIO top-wall cutout removed (GPIO is fully internal; access
// requires removing the rear cover, correct for industrial use)
// 3. Pi cavity depth verified and annotated
// 4. Bezel two-piece connection: corner bosses on rear cover +
// matching through-holes on bezel — intentional removable joint
// ============================================================
// ── SCREEN PARAMETERS ───────────────────────────────────────
scr_w = 236; // screen outer width (mm)
scr_h = 144; // screen outer height (mm)
scr_d = 19; // screen outer depth (mm)
scr_active_w = 222; // active area width (mm) ← confirm with screen datasheet
scr_active_h = 130; // active area height (mm) ← confirm with screen datasheet
scr_mount_x = 75; // screen rear M2.5 hole pattern X (mm) ← verify
scr_mount_y = 75; // screen rear M2.5 hole pattern Y (mm) ← verify
// ── RASPBERRY PI 5 PARAMETERS ────────────────────────────────
pi_w = 85; // Pi board width (mm)
pi_h = 56; // Pi board height (mm)
pi_d = 17; // Pi board + tallest component height (mm)
pi_mnt_x = 58; // Pi mount hole pattern X (mm)
pi_mnt_y = 49; // Pi mount hole pattern Y (mm)
pi_standoff = 5; // standoff height: screen rear face → Pi PCB (mm)
pi_offset_x = 0; // Pi centre X offset from screen centre (mm)
pi_offset_y = 5; // Pi centre Y offset upward from screen centre (mm)
// ── ENCLOSURE PARAMETERS ─────────────────────────────────────
wall = 2.5; // wall thickness throughout (mm)
chamfer = 1.5; // external edge chamfer size (mm)
recess = 1.0; // screen recess depth in front bezel (mm)
gap = 0.3; // bezel ↔ rear cover fit clearance (mm)
// ── VENT PARAMETERS ──────────────────────────────────────────
vent_w = 3; // vent slot width (mm)
vent_l = 20; // vent slot length (mm)
vent_sp = 4; // slot gap edge-to-edge (mm)
soc_vent_sz = 30; // SoC direct-vent zone size (mm, square)
// ── CABLE GLAND PARAMETERS ───────────────────────────────────
gland_count = 2; // number of M16 cable glands
gland_dia = 16.5; // M16 clearance hole diameter (mm)
gland_spacing= 40; // centre-to-centre spacing (mm)
// ── KICKSTAND PARAMETERS ─────────────────────────────────────
// The kickstand is a flat plate + two triangular gussets, integral
// with the rear cover bottom. When the unit stands on the kickstand
// the plate lies flat on the desk and the screen tilts back
// (90 - ks_tilt) degrees from vertical.
ks_tilt = 75; // screen angle from horizontal when standing (deg)
// 75° from horiz = 15° lean-back from vertical
ks_depth = 55; // plate reach behind rear face (mm) — shorter than 002
ks_width = 180; // plate span across enclosure width (mm)
ks_thick = 5; // plate thickness (mm)
ks_gusset_h = 30; // gusset height up the rear cover face (mm)
// ── ASSEMBLY PARAMETERS ──────────────────────────────────────
m3_dia = 3.4; // M3 clearance hole (mm)
insert_dia = 4.2; // M3 heat-set insert OD (mm)
insert_h = 6; // heat-set insert depth (mm)
boss_od = insert_dia + 3.5; // insert boss outer diameter (mm)
corner_inset = wall + boss_od/2 + 1; // corner boss/hole X and Y inset (mm)
// ── DERIVED DIMENSIONS ───────────────────────────────────────
//
// Rear cavity depth check:
// pi_standoff (5) + pi_d (17) + cable headroom (10) = 32 mm → rear_d
// rear_d is the full depth of the rear cover cavity.
// The screen body (scr_d=19 mm) is NOT included in rear_d;
// the rear cover encloses only the space BEHIND the screen rear face.
//
rear_d = pi_standoff + pi_d + 10; // = 32 mm, Pi fits with 10 mm to spare
enc_w = scr_w + 2*wall; // enclosure outer width (241 mm)
enc_h = scr_h + 2*wall; // enclosure outer height (149 mm)
enc_d = rear_d + wall; // rear cover total depth ( 34.5 mm)
// Pi centre in enclosure XY coordinates (wall-offset from screen centre)
pi_enc_cx = wall + scr_w/2 + pi_offset_x; // 120.5 mm with defaults
pi_enc_cy = wall + scr_h/2 + pi_offset_y; // 79.5 mm with defaults
// Z of Pi PCB surface, measured from rear cover rear face
pi_z = wall + pi_standoff; // 7.5 mm with defaults
// Kickstand tip drop: how far below Y=0 the far edge must sit so the
// bottom surface is horizontal when the unit tilts to ks_tilt from horizontal
ks_drop = ks_depth * tan(90 - ks_tilt); // ≈ 14.7 mm for ks_tilt=75
$fn = 48;
// ============================================================
// PRIMITIVES
// ============================================================
// Chamfered rectangular box (all 12 edges, chamfer = c)
module cbox(w, h, d, c=chamfer) {
hull() {
translate([c, c, 0]) cube([w-2*c, h-2*c, d ]);
translate([0, c, c]) cube([w, h-2*c, d-2*c ]);
translate([c, 0, c]) cube([w-2*c, h, d-2*c ]);
}
}
// Rounded-end vent slot: length along Y, width w, extrudes in +Z by d
module slot(len, w, d) {
r = w/2;
hull() {
translate([0, -len/2+r, 0]) cylinder(r=r, h=d);
translate([0, len/2-r, 0]) cylinder(r=r, h=d);
}
}
// Row of n vent slots stepping in X
module vent_row(n, len, w, spacing, depth) {
for(i = [0:n-1])
translate([i*(w+spacing), 0, 0])
slot(len, w, depth);
}
// M3 heat-set insert boss (sits proud from an inner face)
module insert_boss(total_h = insert_h + 4) {
difference() {
cylinder(d=boss_od, h=total_h);
cylinder(d=insert_dia, h=insert_h);
translate([0,0,insert_h]) cylinder(d=m3_dia, h=total_h);
}
}
// ============================================================
// KICKSTAND
// ============================================================
// Geometry (all in rear-cover model space, rear face = Z=0 plane):
//
// Side view (Y-Z plane):
//
// Y=ks_gusset_h ─┐
// │ ← gusset strip on rear face
// Y=0 ───────────┼──────────────────────────────────── rear cover bottom
// │╲ ← gusset triangle
// plate ──┼─╲──────────────────────────────────────────
// (ks_thick)│ ╲ (sloping, thicker at tip)
// ╲ ╲___________________________________
// Y=-(ks_thick+ks_drop) Z=-ks_depth
//
// The plate and gussets are extruded across ks_width in X.
// The gussets (hull triangles) brace the plate against the rear face,
// preventing the kickstand from snapping off at the root.
//
module kickstand() {
ks_x0 = (enc_w - ks_width) / 2;
translate([ks_x0, 0, 0]) {
// ── Main plate ────────────────────────────────────────
// Wedge: root at Z=0 is ks_thick tall;
// tip at Z=-ks_depth is (ks_thick+ks_drop) tall.
// Top surface flush with enclosure bottom (Y=0).
hull() {
// Root strip — along rear face
translate([0, -ks_thick, 0])
cube([ks_width, ks_thick, wall]);
// Tip strip — at full reach, thicker to keep plate horizontal
translate([0, -(ks_thick + ks_drop), -ks_depth])
cube([ks_width, ks_thick + ks_drop, wall]);
}
// ── Triangular gussets (left + right ends) ────────────
// Each gusset is a hull of three patches:
// A – vertical strip up the rear face (height = ks_gusset_h)
// B – small square at plate root (Y=-ks_thick, Z=0)
// C – small square at plate tip (Y=-(ks_thick+ks_drop), Z=-ks_depth)
for(bx = [0, ks_width - ks_thick]) {
hull() {
// A: attachment strip going up the rear face
translate([bx, 0, -wall])
cube([ks_thick, ks_gusset_h, wall]);
// B: plate root corner
translate([bx, -ks_thick, -wall])
cube([ks_thick, ks_thick, wall]);
// C: plate tip corner
translate([bx, -(ks_thick + ks_drop), -ks_depth])
cube([ks_thick, ks_thick, wall]);
}
}
}
}
// ============================================================
// FRONT BEZEL
// ============================================================
// Two-piece design: bezel + rear cover join with M3 screws through
// the bezel corners into heat-set inserts in the rear cover bosses.
// The bezel is intentionally removable for Pi access.
module front_bezel() {
difference() {
cbox(enc_w, enc_h, wall + recess);
// Active display window (full depth cut)
translate([(enc_w - scr_active_w)/2,
(enc_h - scr_active_h)/2,
-0.1])
cube([scr_active_w, scr_active_h, wall+recess+0.2]);
// 1 mm recess pocket — bezel lip grips screen edge
translate([(enc_w - scr_w)/2,
(enc_h - scr_h)/2,
wall])
cube([scr_w, scr_h, recess+0.1]);
// M3 screw clearance holes at 4 corners
for(x = [corner_inset, enc_w - corner_inset])
for(y = [corner_inset, enc_h - corner_inset])
translate([x, y, -0.1])
cylinder(d=m3_dia, h=wall+recess+0.2);
}
}
// ============================================================
// REAR COVER
// ============================================================
module rear_cover() {
n_vent = 6;
vent_block_w = n_vent*(vent_w+vent_sp) - vent_sp;
difference() {
union() {
// Main body
cbox(enc_w, enc_h, enc_d);
// Kickstand (integral, no supports needed — prints face-down)
kickstand();
// Insert bosses at 4 corners (inner rear face, flush with enc_d)
for(x = [corner_inset, enc_w - corner_inset])
for(y = [corner_inset, enc_h - corner_inset])
translate([x, y, enc_d])
rotate([180, 0, 0])
insert_boss();
}
// ── HOLLOW INTERIOR ───────────────────────────────────
// Cavity = full screen footprint, from wall to enc_d (open toward bezel)
translate([wall, wall, wall])
cube([scr_w, scr_h, enc_d]);
// ── PORT CUTOUTS ──────────────────────────────────────
// NOTE: The Pi's port edges are internal (Pi centred on screen).
// Cutouts in the enclosure walls are reference openings for
// short cable extensions routed to the wall. Adjust Y/Z offsets
// to match your exact cable routing once screen mount is verified.
// LEFT WALL — USB-C power + HDMI ×2
// Approximate Y positions relative to Pi bottom edge
pi_bot = pi_enc_cy - pi_h/2;
// USB-C power
translate([-0.1, pi_bot + 3, pi_z + 2]) cube([wall+0.2, 11, 11]);
// HDMI 0
translate([-0.1, pi_bot + 16, pi_z + 2]) cube([wall+0.2, 17, 9]);
// HDMI 1
translate([-0.1, pi_bot + 35, pi_z + 2]) cube([wall+0.2, 17, 9]);
// RIGHT WALL — RJ45 + USB-A ×4
pi_top = pi_enc_cy + pi_h/2;
// RJ45
translate([enc_w-wall-0.1, pi_top - 24, pi_z + 1])
cube([wall+0.2, 22, 16]);
// USB-A ×4 (two stacked pairs)
translate([enc_w-wall-0.1, pi_bot + 2, pi_z + 1])
cube([wall+0.2, 50, 15]);
// BOTTOM WALL — USB-C touch connector on screen side edge
// (screen's own USB-C touch port, not Pi — sits at screen depth)
translate([-0.1,
enc_h/2 - 6,
wall + scr_d - 5])
cube([wall+0.2, 12, 8]);
// ── COOLING VENTS ─────────────────────────────────────
// Bottom intake — 6 slots through bottom wall
translate([enc_w/2 - vent_block_w/2, -0.1, wall + 8])
rotate([-90, 0, 0])
vent_row(n_vent, vent_l, vent_w, vent_sp, wall+0.2);
// Top exhaust — 6 slots through top wall
translate([enc_w/2 - vent_block_w/2,
enc_h - wall + 0.1,
wall + 8])
rotate([90, 0, 0])
vent_row(n_vent, vent_l, vent_w, vent_sp, wall+0.2);
// SoC direct-vent — slot array in rear panel centred over Pi SoC
translate([pi_enc_cx - soc_vent_sz/2,
pi_enc_cy - soc_vent_sz/2,
enc_d - wall - 0.1]) {
n_soc = floor(soc_vent_sz / (vent_w + vent_sp));
for(i = [0:n_soc-1])
translate([i*(vent_w+vent_sp),
soc_vent_sz/2 - vent_l/2,
0])
slot(vent_l, vent_w, wall+0.2);
}
// ── CABLE GLANDS — rear panel, bottom area ────────────
// Two M16 glands through the rear face (Z=0 plane).
// Positioned below Pi, above kickstand root.
for(i = [0:gland_count-1]) {
cx = enc_w/2 + (i - (gland_count-1)/2) * gland_spacing;
translate([cx, wall + gland_dia/2 + 4, -0.1])
cylinder(d=gland_dia, h=wall+0.2);
}
}
}
// ============================================================
// SCENE — exploded assembly view
// Front bezel floats above rear cover to show the joint
// ============================================================
color("DarkSlateGray", 0.9)
translate([0, 0, enc_d + 12])
front_bezel();
color("SlateGray", 0.85)
rear_cover();