pre-bemis
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Marcelo
338
rpi-case/rpi5_industrial_case_004.scad
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338
rpi-case/rpi5_industrial_case_004.scad
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// ============================================================
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// RPi5 Industrial Enclosure — Luckfox DHX-10.1" Touchscreen
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// Version: 004
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// Changes vs 003:
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// 1. KICKSTAND is now a separate, removable piece (own module + color)
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// - Full enc_w width (no shorter ks_width param)
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// - 3 prongs on rear edge that slide into slots in case bottom wall
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// - Tapered prong tips for easy insertion
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// 2. Prong slots added to rear cover bottom wall
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// 3. USB-C touch cutout on left wall REMOVED (per user request)
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// 4. Wall thickness increased 2.5 → 4 mm for rigidity
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// 5. Bezel screw holes now countersunk + clearly sized
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// 6. Insert bosses on rear cover made taller and more prominent
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// so the two-piece (bezel + rear cover) joint is obvious in renders
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// 7. Render shows THREE separate bodies: bezel / rear cover / kickstand
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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 display area width (mm) ← confirm
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scr_active_h = 130; // active display area height (mm) ← confirm
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scr_mount_x = 75; // screen rear M2.5 hole pattern X (mm) ← verify
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scr_mount_y = 75; // screen rear M2.5 hole 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 + 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 PCB (mm)
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pi_offset_x = 0; // Pi centre X offset from screen centre (mm)
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pi_offset_y = 5; // Pi centre Y offset upward from screen centre (mm)
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// ── ENCLOSURE PARAMETERS ─────────────────────────────────────
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wall = 4.0; // wall thickness — increased for rigidity (mm)
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chamfer = 1.5; // external edge chamfer (mm)
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recess = 1.0; // screen recess 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 gap edge-to-edge (mm)
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soc_vent_sz = 30; // SoC direct-vent area size (mm)
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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; // gland centre-to-centre (mm)
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// ── KICKSTAND PARAMETERS ─────────────────────────────────────
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// Separate removable piece — slides onto case bottom via 3 prongs.
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// Wedge shape: thin at rear (prong end), thick at front desk-contact end.
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// When flat on desk the screen sits at ks_tilt degrees from horizontal.
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ks_tilt = 75; // screen angle from horizontal when standing (deg)
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// 75° from horiz ≈ 15° lean-back from vertical
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ks_depth = 60; // plate reach in -Z from case rear face (mm)
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ks_thick = 5; // plate thickness at thin (rear) end (mm)
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// Prong dimensions — 3 prongs slide into 3 slots in case bottom wall
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ks_prong_n = 3; // number of prongs
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ks_prong_w = 12; // prong width (X, mm)
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ks_prong_h = 14; // prong insertion height into cavity (mm)
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ks_prong_t = 5; // prong depth (Z, mm) — same as slot depth
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ks_prong_clr = 0.25; // diametral clearance for fit (mm)
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// ── ASSEMBLY PARAMETERS ──────────────────────────────────────
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m3_dia = 3.4; // M3 clearance hole (mm)
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m3_cs_dia = 6.5; // M3 countersink diameter (mm)
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m3_cs_depth = 3.0; // countersink depth (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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boss_od = 10; // insert boss outer diameter — prominent (mm)
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boss_h = insert_h + 5; // boss total height from inner face (mm)
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// ── DERIVED DIMENSIONS ───────────────────────────────────────
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rear_d = pi_standoff + pi_d + 10; // cavity depth = 32 mm
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enc_w = scr_w + 2*wall; // outer width = 244 mm
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enc_h = scr_h + 2*wall; // outer height = 152 mm
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enc_d = rear_d + wall; // rear cover depth = 36 mm
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// Corner inset for boss/screw centres (keeps them inside the wall)
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corner_inset = wall + boss_od/2 + 0.5; // ≈ 9.5 mm
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// Pi centre in enclosure coordinates
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pi_enc_cx = wall + scr_w/2 + pi_offset_x; // 122 mm
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pi_enc_cy = wall + scr_h/2 + pi_offset_y; // 81 mm
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pi_z = wall + pi_standoff; // 9 mm (Pi PCB Z from rear face)
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// Kickstand geometry
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ks_drop = ks_depth * tan(90 - ks_tilt); // ≈ 16 mm tip drop
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// Prong slot Z position — prongs sit right at the case rear face
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ks_prong_z = 0; // prong rear face flush with case Z=0
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$fn = 48;
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// ============================================================
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// PRIMITIVES
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// ============================================================
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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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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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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
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module insert_boss() {
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difference() {
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cylinder(d=boss_od, h=boss_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=boss_h);
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}
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}
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// Countersunk M3 hole (for bezel face)
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module m3_countersunk(depth) {
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cylinder(d=m3_dia, h=depth+0.1);
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translate([0, 0, depth - m3_cs_depth])
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cylinder(d1=m3_dia, d2=m3_cs_dia, h=m3_cs_depth+0.1);
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}
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// Prong slot — cut from bottom wall, prong inserts up into cavity
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module prong_slot() {
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translate([-ks_prong_w/2 - ks_prong_clr,
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-0.1,
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ks_prong_z - ks_prong_clr])
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cube([ks_prong_w + 2*ks_prong_clr,
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ks_prong_h + wall + 0.2,
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ks_prong_t + 2*ks_prong_clr]);
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}
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// ============================================================
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// KICKSTAND (separate removable piece)
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// ============================================================
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//
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// Side view (Y-Z plane, unit standing on kickstand):
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//
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// Y=0 (case bottom) ─────────────────────────────
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// │↑↑↑ prongs (insert into case)
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// Y=-ks_thick ─────┼─────────────────────────────────┐
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// \ wedge plate (bottom surface │
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// \ angled so it lies flat when │
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// Y=-(ks_thick+ks_drop)\ screen tilts to ks_tilt) │
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// └──────────────────────────────┘
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// Z=0 Z=-ks_depth
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//
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module kickstand() {
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ks_front_h = ks_thick + ks_drop; // total height at the front (desk-contact) edge
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// Main wedge plate
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hull() {
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// Rear (thin) edge, at Z=0 — where prongs attach
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translate([0, -ks_thick, 0])
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cube([enc_w, ks_thick, wall]);
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// Front (thick) edge, at Z=-ks_depth — rests on desk
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translate([0, -ks_front_h, -ks_depth])
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cube([enc_w, ks_front_h, wall]);
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}
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// Three prongs — evenly spaced, rise from Y=0 into case cavity
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for(i = [0:ks_prong_n-1]) {
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px = enc_w * (i+1) / (ks_prong_n+1);
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translate([px - ks_prong_w/2, 0, ks_prong_z]) {
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// Tapered tip so prong slides in easily
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hull() {
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// Base: full-width prong up to the tapered section
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cube([ks_prong_w,
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ks_prong_h - 2,
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ks_prong_t]);
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// Tip: narrowed 1 mm per side for 45° insertion chamfer
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translate([1, ks_prong_h - 2, 0])
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cube([ks_prong_w - 2, 2, ks_prong_t]);
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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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// Removable front frame — held to rear cover by 4× M3 screws
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// through countersunk holes at each corner, threading into
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// heat-set inserts pressed into the rear cover's corner bosses.
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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
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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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// 1 mm recess pocket — bezel lip grips screen edge
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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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// 4× M3 countersunk screw holes at corners
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for(x = [corner_inset, enc_w - corner_inset])
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for(y = [corner_inset, enc_h - corner_inset])
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translate([x, y, 0])
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m3_countersunk(wall + recess);
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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;
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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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// ── Insert bosses: 4 corners, proud on inner rear face ──
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// These are clearly visible tall cylinders that receive the
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// heat-set inserts; M3 screws from the bezel thread into them.
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for(x = [corner_inset, enc_w - corner_inset])
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for(y = [corner_inset, enc_h - corner_inset])
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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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// LEFT WALL — USB-C power + HDMI ×2 (Pi left short-edge ports)
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pi_bot = pi_enc_cy - pi_h/2;
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// USB-C power
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translate([-0.1, pi_bot + 3, pi_z + 2]) cube([wall+0.2, 11, 11]);
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// HDMI 0
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translate([-0.1, pi_bot + 16, pi_z + 2]) cube([wall+0.2, 17, 9]);
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// HDMI 1
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translate([-0.1, pi_bot + 35, pi_z + 2]) cube([wall+0.2, 17, 9]);
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// RIGHT WALL — RJ45 + USB-A ×4 (Pi right short-edge ports)
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pi_top = pi_enc_cy + pi_h/2;
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// RJ45
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translate([enc_w-wall-0.1, pi_top - 24, pi_z + 1])
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cube([wall+0.2, 22, 16]);
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// USB-A ×4
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translate([enc_w-wall-0.1, pi_bot + 2, pi_z + 1])
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cube([wall+0.2, 50, 15]);
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// NOTE: USB-C touch cutout (screen side) REMOVED per v004 request.
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// GPIO header is internal — access by removing bezel + rear cover.
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// ── COOLING VENTS ─────────────────────────────────────
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// Bottom intake slots (through bottom wall)
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translate([enc_w/2 - vent_block_w/2, -0.1, 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 (through top wall)
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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 on rear panel
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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, bottom area ────────────
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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, wall + gland_dia/2 + 4, -0.1])
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cylinder(d=gland_dia, h=wall+0.2);
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}
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// ── KICKSTAND PRONG SLOTS — bottom wall ───────────────
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// 3 slots matching kickstand prong positions and sizes.
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// Slots pass through the bottom wall into the cavity so prongs
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// engage wall + (ks_prong_h - wall) mm inside the cavity.
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for(i = [0:ks_prong_n-1]) {
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px = enc_w * (i+1) / (ks_prong_n+1);
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translate([px, 0, ks_prong_z])
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prong_slot();
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}
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}
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}
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// ============================================================
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// SCENE — three separate bodies, exploded for clarity
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// ============================================================
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// Front bezel — exploded up, face toward viewer
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color("DarkSlateGray", 0.92)
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translate([0, 0, enc_d + 14])
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front_bezel();
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// Rear cover — at origin
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color("SlateGray", 0.88)
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rear_cover();
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// Kickstand — exploded below, separate piece
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color("DimGray", 0.85)
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translate([0, -(ks_thick + ks_drop + 20), 0])
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kickstand();
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