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remote-rig/hardware/DESIGN_PIPELINE.md
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# RemoteRig Hardware Design Pipeline
> Living queue for 3D-printed / physical hardware design work.
## Active / Ready for CAD prototype
### Camera node case v4 — upright status panel + strap mount
**Status:** Parametric OpenSCAD source created; body/lid/preview STLs exported and validated watertight. Ready for CAD review, exact part measurement, and first prototype print.
**Files:**
- `hardware/case/camera-node-case-v4.scad`
- `hardware/case/camera-node-case-v4-body.scad`
- `hardware/case/camera-node-case-v4-lid.scad`
- `hardware/case/camera-node-case-v4-preview.scad`
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- `hardware/case/camera-node-case-v4-front-review.scad`
- `hardware/case/camera-node-case-v4-body.stl`
- `hardware/case/camera-node-case-v4-lid.stl`
- `hardware/case/camera-node-case-v4-preview.stl`
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- `hardware/case/camera-node-case-v4-front-review.stl`
**Design direction:**
- Stand-mounted upright camera node enclosure; the case still does **not** mount to the GoPro.
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- Visual direction now matches the original green appliance-style reference: tall vertical body, large inset front panel, centered OLED near the upper third, blank middle area, two long rounded lower slots, bottom USB-C female power input, right-side USB-A female passthrough power port for the GoPro, and left-side IPEX/U.FL antenna pigtail/connector exit opposite the USB-A.
- This replaces the rejected wide/low generic electronics-box layout from the first v4 attempt.
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- Primary mounting is reusable cloth zip ties / Velcro straps through two low-profile vertical rear brackets with long lateral side-feed openings, not a clamp/dovetail.
- Front has a recessed/flush full-height service lid similar to a field-service status panel.
- Lid includes cutouts for:
- 1.3-inch OLED/status screen.
- separate 3 mm power LED.
- single 3 mm RGB status LED replacing red/green status LEDs.
- small rocker on/off switch.
- two long rounded lower front slots styled after the reference.
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- Front-panel screen, LED, rocker, and lower-slot openings are actual through-cuts through the full lid and locating lip so the back side of the printed lid is not skinned over.
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- Body includes screw bosses, recessed lid pocket, lid locating geometry, a bottom USB-C female power inlet cutout, a right-side USB-A female passthrough power cutout, a left-side 5.0 mm prototype IPEX/U.FL antenna pigtail/connector through-hole with shallow exterior recess, and two vertical external rear zip-tie/Velcro brackets to resist rotation on a stand. The zip ties feed laterally through long side windows behind the raised bridge faces; the old top-to-bottom feed-through tunnel is intentionally closed by top/bottom anchor pads.
- Internal envelope is sized for known module dimensions plus service clearance:
- ESP32-C3 Super Mini: 22.5 × 18 mm.
- ESP-01S: ~24.7 × 14.3 × 12 mm.
**Prototype display content target:**
```text
CAM 03 REC ●
BAT 87% LINK OK
00:12:34
```
**Prototype dimensions to validate before production:**
- Exact 1.3-inch OLED module dimensions:
- PCB width/height/thickness.
- active display/window width/height.
- connector side and ribbon/header clearance.
- mounting-hole positions, if using module screws or adhesive tape.
- Rocker switch:
- snap-in cutout width/height.
- bezel/flange size.
- required panel thickness range.
- rear depth and terminal clearance.
- LEDs:
- preferred holder/bezel style, if any.
- final hole diameter for 3 mm PWR LED and 3 mm RGB STAT LED.
- current-limiting resistor placement.
- Wiring/service:
- USB cable diameter and bend radius.
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- bottom USB-C female panel/breakout connector flange, body depth, and mounting requirements.
- right-side USB-A female panel/breakout connector flange, body depth, and mounting requirements for GoPro 5 V passthrough.
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- left-side IPEX/U.FL antenna pigtail/bulkhead exact outside diameter, retention/flange needs, bend radius, strain relief, and whether the current 5.0 mm prototype through-hole plus 8.5 mm shallow exterior recess should change before production.
- actual regulator/power distribution board footprint if used.
- Fasteners:
- M2 vs M2.5 vs self-tapping screws for lid.
- pilot diameter, screw length, and head/counterbore diameter.
- Mounting straps:
- cloth zip-tie / Velcro width and thickness.
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- prototype rear side-feed opening: ~40 mm long vertical side window × ~3.8 mm strap-thickness clearance behind each raised bridge, with each visible vertical bracket ~8.5 mm wide × 50 mm tall.
- whether two strap paths are enough to prevent case rotation on the expected stand diameter.
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- whether rear vertical bracket/window edges need larger radii or TPU/silicone sleeve protection.
- Printability:
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- rear vertical zip-tie bracket top/bottom anchor-pad and bridge strength, and whether the lateral side-feed openings print cleanly without supports.
- body/lid fit after PETG shrinkage.
- lid lip clearance and screw boss robustness.
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- USB-C/USB-A and IPEX antenna exit cutout edge quality, wall strength, and connector retention/strain relief.
**Suggested OpenSCAD validation/export commands:**
```bash
openscad -o /tmp/camera-node-case-v4-body.stl hardware/case/camera-node-case-v4-body.scad
openscad -o /tmp/camera-node-case-v4-lid.stl hardware/case/camera-node-case-v4-lid.scad
openscad -o /tmp/camera-node-case-v4-preview.stl hardware/case/camera-node-case-v4-preview.scad
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openscad -o /tmp/camera-node-case-v4-front-review.stl hardware/case/camera-node-case-v4-front-review.scad
```
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Latest validation: OpenSCAD reports `Simple: yes`; trimesh confirms body, lid, preview, and front-review STLs are watertight. Body and lid each export as a single connected printable component; preview includes separate non-print board/connector guide volumes by design. A rear-bracket sanity check confirms both vertical brackets have clear non-solid lateral X-direction side-feed volumes behind the raised bridge faces, while the rear wall, bridge faces, and top/bottom anchor pads remain solid. The left-side IPEX/U.FL antenna hole is a through-wall cut to the interior cavity, not a blind exterior pocket.
Or with the main parametric selector:
```bash
openscad -D 'part="body"' -o /tmp/camera-node-case-v4-body.stl hardware/case/camera-node-case-v4.scad
openscad -D 'part="lid"' -o /tmp/camera-node-case-v4-lid.stl hardware/case/camera-node-case-v4.scad
openscad -D 'part="preview"' -o /tmp/camera-node-case-v4-preview.stl hardware/case/camera-node-case-v4.scad
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openscad -D 'part="front_review"' -o /tmp/camera-node-case-v4-front-review.stl hardware/case/camera-node-case-v4.scad
```
## Prior prototype reference
### Tripod electronics case v3
**Status:** Historical design reference. In this checkout, previous v3 SCAD/STL files are not present; v4 starts a new `hardware/case/` CAD source set.
**Previous design notes:**
- Held ESP32 + ESP8266 stack.
- Screw-on lid with vent slots.
- Rear dovetail-style rail/socket interface.
- Separate screw-tightened tripod clamp sized around a 35 mm stand/pole.
- Clamp used M3 hardware: one M3 screw across the clamp mouth, with an M3 nut trap.
**Reasons superseded by v4:**
- User requested front status/service panel with OLED, LEDs, and rocker switch.
- Single RGB status LED replaces separate red/green status LEDs.
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- Rear strap pass-through loops are simpler and more adaptable than a dedicated clamp/dovetail for field stands.
## Backlog
### 10.1-inch touchscreen + Raspberry Pi Zero case
**Status:** Specific display identified; mechanical measurements needed before CAD.
**Goal:** A printable enclosure for the RemoteRig hub/control panel using a 10.1-inch touchscreen and Raspberry Pi Zero / Zero 2 W.
**Display target:**
- Vendor/model: HZWDONE Raspberry Pi Screen 10.1" Touchscreen
- Resolution: 1024×600
- Interface: HDMI portable monitor
- Mounting: includes fixing holes
- Compatibility listing: Raspberry Pi 5/4/3B/B+ and Windows 11/10/8
**Initial assumptions to validate:**
- Compute: Raspberry Pi Zero / Zero 2 W mounted behind or below the display.
- Use case: RemoteRig local monitor/control panel at field recording setup.
- Likely needs: front bezel, rear electronics cavity, Pi mounting posts, HDMI/USB/power cable exits, strain relief, ventilation, and optional tripod/stand mounting.
- Because this is a 10.1" panel, design should prioritize rigidity: thicker bezel ribs, rear standoffs, and possibly a two-piece shell instead of a small snap case.
**Required measurements before CAD:**
- Product link or datasheet for the exact HZWDONE 10.1" variant.
- Screen/PCB outer dimensions: width, height, thickness.
- Active display opening dimensions.
- Fixing-hole locations, hole diameter, and screw size.
- Connector locations/orientation for HDMI, USB touch, and power.
- Whether the driver/controller board is integrated with the display PCB or separate.
- Pi Zero orientation, port access requirements, and whether GPIO/header must remain accessible.
- Power connector position and desired cable routing.
- Mounting preference: desktop kickstand, tripod clamp, VESA-style holes, handle, or combination.
**Proposed design approach:**
1. Create `hardware/display-case/`.
2. Build a parametric OpenSCAD model with measured display/Pi dimensions.
3. Split into printable parts: front bezel, rear shell, Pi/controller tray, optional stand/tripod mount.
4. Validate STLs with OpenSCAD + trimesh.
5. Upload generated STL/SCAD artifacts to Seafile.