2026-05-28 06:58:40 -04:00
11 changed files with 209113 additions and 85 deletions
@@ -2,30 +2,126 @@
 > Living queue for 3D-printed / physical hardware design work.
-## Active / Ready for prototype print
+## 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`
 - `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`
 - `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.
 - 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.
 - 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.
 - 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.
 - 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.
  - 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.
  - 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.
  - 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.
  - whether rear vertical bracket/window edges need larger radii or TPU/silicone sleeve protection.
 - Printability:
  - 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.
  - 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
 openscad -o /tmp/camera-node-case-v4-front-review.stl hardware/case/camera-node-case-v4-front-review.scad
 ```
 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
 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:** STL generated and validated watertight.
+**Status:** Historical design reference. In this checkout, previous v3 SCAD/STL files are not present; v4 starts a new `hardware/case/` CAD source set.
-**Files:**
+**Previous design notes:**
 - `hardware/case/tripod-case-v3.scad`
 - `hardware/case/case-body-v3.stl`
 - `hardware/case/case-lid-v3.stl`
 - `hardware/case/tripod-clamp-v3.stl`
 - `hardware/case/full-case-preview-v3.stl`
-**Design notes:**
+- Held ESP32 + ESP8266 stack.
 - Holds 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 uses M3 hardware: one M3 screw across the clamp mouth, with an M3 nut trap.
+- Clamp used M3 hardware: one M3 screw across the clamp mouth, with an M3 nut trap.
-**Prototype questions:**
+**Reasons superseded by v4:**
- Does the clamp close enough on smaller tripod legs, or do we need swappable inserts?
+
- Does the dovetail hold under vibration without a retention screw?
+- User requested front status/service panel with OLED, LEDs, and rocker switch.
- Are USB/LED/UART cutouts in the correct orientation for the actual boards?
+- Single RGB status LED replaces separate red/green status LEDs.
 - Rear strap pass-through loops are simpler and more adaptable than a dedicated clamp/dovetail for field stands.
 ## Backlog
@@ -36,6 +132,7 @@
 **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
@@ -43,12 +140,14 @@
 - 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.
@@ -60,6 +159,7 @@
 - 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.
@@ -1,89 +1,158 @@
 # RemoteRig — Camera Node Hardware Design
-> **Version:** 0.2.0 | **Status:** Draft  
+> **Version:** 0.3.0 | **Status:** v4 CAD prototype ready for measurement/print validation
-> **Target:** GoPro Hero 3 Black/Silver + ESP8266 + ESP32 + USB power bank
+> **Target:** GoPro Hero 3 Black/Silver + ESP32-C3 Super Mini + ESP-01S + USB power bank
 ## Overview
-Each camera node is two ESP boards in a small case that clips to the tripod/stand. The case **does not attach to the camera** — only to the stand. Powered by a standard USB power bank.
+Each camera node is two ESP boards in a small upright stand-mounted case. The case **does not attach to the camera**; it straps to a tripod/lighting stand with reusable cloth zip ties / Velcro straps. Powered by a standard USB power bank.
 ```
     ┌─────────────────┐
-     │  USB Power Bank │── USB ──→ GoPro (power only)
+     │  USB Power Bank │
-     │  (off-the-shelf)│── USB ──→ ESP32 + ESP8266 (shared)
+     │  (off-the-shelf)│
-     └─────────────────┘
+     └────────┬────────┘
-              │
+              │ USB-C cable into bottom USB-C female input
-     ┌────────┴────────┐
+              ▼
-     │  Tripod Case    │ ← clips to stand leg
+     ┌─────────────────────────────────────┐
-     │  ┌────────────┐ │
+     │  Camera Node Case v4                │ ← Velcro/cloth straps to stand
-     │  │ ESP8266    │ │ ← Wi-Fi → GoPro AP (10.5.5.1)
+     │  ┌──────────────────────────────┐   │
-     │  │ (camera)   │ │
+     │  │ Flush/recessed service lid   │   │
-     │  ├────────────┤ │ ← UART between boards
+     │  │ 1.3 OLED: CAM/REC/BAT/LINK   │   │
-     │  │ ESP32      │ │ ← Wi-Fi → Travel Router
+     │  │ PWR LED + RGB STAT LED       │   │
-     │  │ (MQTT)     │ │
+     │  │ Small rocker power switch    │   │
-     │  └────────────┘ │
+     │  └──────────────────────────────┘   │
-     └─────────────────┘
+     │  ESP-01S camera bridge ↔ ESP32-C3   │
     │  side USB-A female power output ────┼── USB cable ──→ GoPro power
     └─────────────────────────────────────┘
 ```
 ## Bill of Materials
 | Item | Qty | Cost | Notes |
 |------|-----|------|-------|
-| ESP32 Dev Board | 1 | ~$5 | MQTT bridge — talks to hub |
+| ESP32-C3 Super Mini | 1 | ~$4–$6 | MQTT / hub-side bridge; known board envelope 22.5 × 18 mm |
-| ESP8266 D1 Mini | 1 | ~$3 | Camera bridge — talks to GoPro |
+| ESP-01S / ESP8266 module | 1 | ~$2–$3 | Camera-side GoPro Wi-Fi bridge; known envelope ~24.7 × 14.3 × 12 mm |
-| USB power bank (5000mAh+) | 1 | ~$10 | Powers both boards + GoPro |
+| 1.3-inch OLED/status screen | 1 | ~$4–$8 | Prototype CAD assumes ~31 × 16 mm visible window / ~37 × 22 mm panel recess; confirm exact module |
-| Micro-USB cable (short) | 2 | ~$2 | Power bank → boards + GoPro |
+| 3 mm power LED | 1 | <$1 | Separate always-power/5V indicator |
-| Jumper wires F-F | 3 | ~$0.25 | UART TX/RX/GND between boards |
+| 3 mm RGB status LED | 1 | <$1 | Replaces separate red/green status LEDs; firmware can map node states to color |
-| PETG filament | ~25g | ~$0.50 | 3D printed case |
+| Small rocker switch | 1 | ~$1–$3 | On/off switch; prototype CAD assumes 13 × 19 mm snap-in opening |
-| Velcro strap (small) | 1 | ~$0.25 | Secure power bank to stand |
+| USB-C female panel/breakout connector | 1 | ~$1–$4 | Bottom power input; prototype CAD assumes ~10.5 × 4.5 mm rounded visible opening plus shallow underside recess; measure purchased part |
 | USB-A female panel/breakout connector | 1 | ~$1–$4 | Right-side GoPro power passthrough output; prototype CAD assumes ~16 × 8 mm side opening; measure purchased part |
 | IPEX/U.FL antenna pigtail or bulkhead lead | 1 | TBD | Left-side antenna exit opposite the USB-A port; prototype CAD assumes a 5.0 mm circular through-hole plus shallow exterior recess; measure exact pigtail/bulkhead diameter before production |
 | USB power bank (5000 mAh+) | 1 | ~$10 | Powers camera node and GoPro |
 | Short USB cables / wiring | as needed | ~$2–$5 | Power bank → node USB-C input; node 5 V passthrough → USB-A female → GoPro USB cable; internal power/signal wiring |
 | M2 or small self-tapping screws | 4 | <$1 | Front service lid screws; pilot holes are parametric |
 | PETG filament | ~35–50 g | ~$1 | 3D printed case body + lid |
 | Reusable cloth zip ties / Velcro straps | 2 | ~$1 | Primary stand mount through rear vertical zip-tie brackets with lateral side-feed openings |
-**Total per node:** ~$21 (+ GoPro already owned)
+**Total per node:** roughly ~$25–$35 plus GoPro and power bank, depending on display/switch choice.
 ## 3D Printed Case
-**Current source:** `hardware/case/tripod-case-v3.scad`
+**Current source:** `hardware/case/camera-node-case-v4.scad`
 **Pipeline:** `hardware/DESIGN_PIPELINE.md`
-Four exported prototype files:
+The current v4 CAD replaces the rejected wide/low electronics-box layout with a tall appliance-style enclosure matching the original upright reference: a clean vertical body, large inset front panel, OLED near the top, open blank middle area, two long rounded lower slots, a bottom USB-C female power input, a right-side USB-A female passthrough power port for the GoPro, and a left-side IPEX/U.FL antenna pigtail/connector hole opposite the USB-A. It also replaces the v3 clamp/dovetail concept with a simpler strap-mounted field enclosure:
-1. **Case body** — holds both boards stacked, cable ports, rear dovetail-style receiver
+
-2. **Case lid** — screw-on cover with ventilation
+1. **Case body** — shell sized around ESP32-C3 Super Mini + ESP-01S with service/wiring clearance.
-3. **Tripod clamp** — separate screw-tightened C-clamp sized around a 35mm stand/pole
+2. **Flush/recessed full-height front service lid** — screw-on front panel with locating lip and a restrained raised/recessed border.
-4. **Full preview** — combined visualization STL only, not intended as the print job
+3. **Front panel controls/indicators**:
   - 1.3-inch OLED/status screen window.
   - 3 mm **PWR** LED.
   - single 3 mm **RGB STAT** LED for state-dependent colors.
   - small rectangular rocker switch cutout.
   - two long rounded lower front slots styled after the reference appliance face.
 4. **Rear vertical zip-tie pass-through brackets** — two low-profile external brackets, one left and one right of center, with top/bottom anchor pads and long vertical side-access openings. Zip ties feed laterally in the X direction behind each raised bridge face instead of top-to-bottom, while the rear wall stays sealed.
 5. **USB power ports** — bottom USB-C female power input and right-side USB-A female passthrough power output for a GoPro USB power cable.
 6. **Left-side antenna exit** — prototype 5.0 mm round through-wall IPEX/U.FL antenna pigtail/connector clearance, placed opposite the right-side USB-A port at the same vertical position, with a shallow exterior circular recess for visual/exit relief. Measure the actual antenna pigtail/bulkhead before production.
 ### Export wrappers
 Simple per-part OpenSCAD wrappers are included:
 - `hardware/case/camera-node-case-v4-body.scad`
 - `hardware/case/camera-node-case-v4-lid.scad`
 - `hardware/case/camera-node-case-v4-preview.scad`
 - `hardware/case/camera-node-case-v4-front-review.scad`
 Example CLI exports, if OpenSCAD is installed:
 ```bash
 openscad -o hardware/case/camera-node-case-v4-body.stl hardware/case/camera-node-case-v4-body.scad
 openscad -o hardware/case/camera-node-case-v4-lid.stl hardware/case/camera-node-case-v4-lid.scad
 openscad -o hardware/case/camera-node-case-v4-preview.stl hardware/case/camera-node-case-v4-preview.scad
 openscad -o hardware/case/camera-node-case-v4-front-review.stl hardware/case/camera-node-case-v4-front-review.scad
 ```
 Or render the main file directly:
 ```bash
 openscad -D 'part="body"' -o hardware/case/camera-node-case-v4-body.stl hardware/case/camera-node-case-v4.scad
 openscad -D 'part="lid"' -o hardware/case/camera-node-case-v4-lid.stl hardware/case/camera-node-case-v4.scad
 openscad -D 'part="preview"' -o hardware/case/camera-node-case-v4-preview.stl hardware/case/camera-node-case-v4.scad
 openscad -D 'part="front_review"' -o hardware/case/camera-node-case-v4-front-review.stl hardware/case/camera-node-case-v4.scad
 ```
 `camera-node-case-v4-preview.stl` is the seated fit-check assembly. `camera-node-case-v4-front-review.stl` is a non-print review layout with the body and front panel separated/angled so the OLED, LED, rocker, USB connector, and lower-slot cutouts are obvious in a slicer.
 ### Print Settings
- **Material:** PETG preferred for heat/outdoor use and clamp flex
+
- **Layer:** 0.2mm | **Infill:** 20% gyroid minimum; 35%+ recommended for clamp
+- **Material:** PETG preferred for heat/outdoor use and strap-tab durability.
- **Supports:** Likely yes for clamp ears / dovetail overhangs depending on slicer orientation
+- **Layer:** 0.2 mm typical.
- **Post-processing:** M3x8mm screws for lid (4x), one M3 screw + M3 nut for clamp tightening
+- **Infill:** 20% gyroid minimum; 30%+ recommended around rear vertical zip-tie bracket anchor pads/bridges.
 - **Supports:** likely minimal/none depending on orientation; verify the rear lateral side-feed openings remain open and check USB-C/USB-A port cutouts in slicer.
 - **Post-processing:** fit 4 lid screws; deburr OLED/LED/switch and IPEX antenna exit cutouts; clear any stringing inside the rear side-feed openings; soften strap-contact edges if the printed radius is too sharp for cloth ties.
 ## Expected Status Screen Content
 Preferred 1.3-inch OLED layout/content style:
 ```text
 CAM 03   REC ●
 BAT 87%  LINK OK
 00:12:34
 ```
 Suggested fields:
 - `CAM` / node ID.
 - `REC` state with a clear recording indicator.
 - Battery percentage or supply estimate.
 - `LINK OK` / degraded / disconnected state.
 - Recording/session timer.
 ## Wiring
-```
+```text
 USB Power Bank
-  ├── USB-A → Micro-USB cable → ESP32 USB port
+  └── USB-C cable → bottom USB-C female input on Camera Node Case
-  │                              (powers ESP32, shared 5V rail)
+          ├── rocker switch → node power rail
-  │
+          ├── PWR LED indicator
-  ├── USB-A → Micro-USB cable → GoPro USB port
+          ├── ESP32-C3 Super Mini
-  │                              (power only — no data)
+          ├── ESP-01S / ESP8266
-  │
+          ├── 1.3-inch OLED display
-  └── (ESP8266 powered via ESP32 3.3V pin, or via shared USB)
+          ├── RGB status LED
          └── 5 V passthrough rail → side USB-A female output
                                      └── USB cable → GoPro USB port
                                          (power only — no data)
-UART (inside case):
+UART / control inside case:
-  ESP8266 TX (GPIO1)  ──→ ESP32 RX (GPIO16)
+  ESP-01S TX  ──→ ESP32-C3 RX
-  ESP8266 RX (GPIO3)  ←── ESP32 TX (GPIO17)
+  ESP-01S RX  ←── ESP32-C3 TX
-  ESP8266 GND ─────────── ESP32 GND
+  ESP-01S GND ─── ESP32-C3 GND
 ```
-**Power note:** Both boards can be powered from a single USB cable if the ESP32's VIN/5V pin is bridged to the ESP8266's VIN. Alternatively, use a USB Y-splitter cable.
+**Power note:** exact wiring depends on the regulator/power board used. Confirm OLED voltage, LED current limiting, and whether the rocker switches USB 5 V input or a regulated node rail.
 ## Wi-Fi Topology
-```
+```text
-GoPro Hero 3 ──(AP @ 10.5.5.1)──→ ESP8266 (camera bridge)
+GoPro Hero 3 ──(AP @ 10.5.5.1)──→ ESP-01S / ESP8266 camera bridge
                                             │
                                        UART │ (inside case)
                                             │
-Travel Router ──(AP)─────────────────→ ESP32 (MQTT bridge)
+Travel Router ──(AP)────────────────────→ ESP32-C3 MQTT bridge
 (10.60.1.1)                                │
                                             │
                                        MQTT │
@@ -91,22 +160,32 @@ Travel Router ──(AP)─────────────────→ E
                                   Pi Hub (10.60.1.56)
 ```
-The ESP8266 and GoPro talk over Wi-Fi — **no data cable between them**. The only cable to the GoPro is USB power from the battery pack.
+The ESP8266/ESP-01S and GoPro talk over Wi-Fi. The only cable to the GoPro is USB power from the case side USB-A passthrough port.
 ## Field Setup
-1. **Mount GoPro** on tripod/stand
+1. Mount GoPro on tripod/stand.
-2. **Clip case** to tripod leg
+2. Feed two reusable cloth zip ties / Velcro straps laterally through the long side openings behind the rear vertical brackets.
-3. **Connect power bank** via USB to case + GoPro
+3. Strap the case to a tripod/stand leg; use both strap paths to resist rotation.
-4. **Power on** — ESP32 auto-connects to travel router, ESP8266 auto-connects to GoPro
+4. Connect the power bank to the case bottom USB-C input; connect the GoPro USB power cable to the case side USB-A passthrough output.
-5. **Monitor** from `http://10.60.1.56:8080`
+5. Toggle rocker switch on.
 6. Verify PWR LED, RGB status LED, and OLED status: camera ID, REC state, battery, link, timer.
 7. Monitor from `http://10.60.1.56:8080`.
 ## Case Dimensions
-| | W × D × H (mm) |
+Prototype v4 nominal CAD dimensions:
 | Part / feature | W × D × H (mm) |
 |---|---|
-| Case body external | ~56.8 × 38.2 × 19.0 |
+| Case shell external | ~56 × 36 × 82 |
-| Lid external | ~56.8 × 32.8 × 4.0 |
+| Case with rear zip-tie brackets | ~56 × 41.2 × 82 |
-| Tripod clamp | ~43.0 × 56.9 × 16.0 |
+| Front recessed lid | visible panel ~48 × 2 × 74; total with locating lip ~48 × 3 × 74 |
-| Clamp pole fit | Nominal 35mm; smaller poles TBD / may need inserts |
+| OLED visible window assumption | ~31 × 16 |
-| Total weight | TBD after prototype print |
+| Rocker cutout assumption | ~13 × 19 |
 | Bottom USB-C power input cutout | ~10.5 × 4.5 opening with ~18 × 10 shallow underside recess |
 | Right-side USB-A passthrough cutout | ~16 Y/front-back × 8 Z opening through side wall |
 | Rear vertical zip-tie brackets | two external side-feed brackets, each ~8.5 mm wide × 50 mm tall; lateral tunnel has ~40 mm vertical side-window length × ~3.8 mm strap-thickness clearance behind the raised bridge |
 | Board clearance targets | ESP32-C3 22.5 × 18 mm + ESP-01S 24.7 × 14.3 × 12 mm plus wiring/service clearance |
 These dimensions are placeholders for the first CAD prototype. Measure the actual OLED module, rocker switch, LEDs, screws, USB-C/USB-A connector flanges and body depths, USB cable bend radius, and strap width/thickness before committing to production prints.
@@ -0,0 +1,4 @@
 // Export wrapper for RemoteRig camera node case v4 body.
 use <camera-node-case-v4.scad>
 camera_node_body_v4();
@@ -0,0 +1,4 @@
 // Export wrapper for RemoteRig camera node case v4 front-facing review layout.
 use <camera-node-case-v4.scad>
 camera_node_front_review_v4();
@@ -0,0 +1,4 @@
 // Export wrapper for RemoteRig camera node case v4 front service lid/status panel.
 use <camera-node-case-v4.scad>
 camera_node_lid_v4();
@@ -0,0 +1,4 @@
 // Export wrapper for RemoteRig camera node case v4 assembly preview.
 use <camera-node-case-v4.scad>
 camera_node_preview_v4();
@@ -0,0 +1,309 @@
 // RemoteRig camera node case v4
 // Upright appliance-style OpenSCAD prototype for a strap-mounted camera node.
 // Units: millimeters. Coordinate system: X=width, Y=depth/front-back, Z=height.
 // Front/service lid is on the -Y face. Rear side-feed zip-tie brackets are on the +Y face.
 //
 // v4 visual direction: tall/upright appliance/control box matching the original
 // reference image, replacing the rejected wide, low generic electronics box.
 // Nominal body: 56 W x 36 D x 82 H mm; with low rear zip-tie loops ~41 D.
 //
 // Prototype assumptions to confirm against purchased parts:
 // - 1.3 inch OLED module/window opening: 31 x 16 mm visible window, 37 x 22 mm panel recess.
 // - Small rocker switch cutout: 13 x 19 mm rectangular snap-in opening.
 // - LEDs: two 3 mm panel LEDs (PWR + RGB STAT) with 3.2 mm holes.
 // - Boards: ESP32-C3 Super Mini 22.5 x 18 mm, ESP-01S 24.7 x 14.3 x 12 mm.
 // - USB-C bottom power inlet and side USB-A passthrough are panel/breakout placeholders;
 //   measure purchased connector flanges/bodies before production prints.
 // - Left-side IPEX/U.FL antenna pigtail connector/lead hole is a prototype 5.0 mm
 //   circular through-wall clearance; measure the final bulkhead/lead before production.
 $fn = 56;
 // ----- Main enclosure parameters -----
 case_w = 56;                 // upright appliance-style external width
 case_d = 36;                 // depth for module stack + wiring clearance
 case_h = 82;                 // tall vertical appliance-style height
 wall = 2.2;
 corner_r = 4.0;
 front_recess_d = 2.0;        // lid sits in this front pocket, nominally flush
 lid_clearance = 0.35;
 lid_w = case_w - 8;          // nearly full-height/front-width inset panel
 lid_h = case_h - 8;
 lid_t = 2.0;
 lid_lip_t = 1.2;             // locating lip protrudes inside service opening
 service_opening_w = lid_w - 10.0;
 service_opening_h = lid_h - 16.0;
 // Hardware
 screw_d = 2.4;               // M2 self-tapping / pilot; confirm hardware
 screw_head_d = 4.6;
 boss_d = 6.0;
 boss_len = 8.0;
 // Front panel components
 oled_window_w = 31.0;
 oled_window_h = 16.0;
 oled_bezel_w = 37.0;         // shallow recessed visual outline around window
 oled_bezel_h = 22.0;
 oled_z = 53.0;               // upper third, clear of top screw counterbores
 led_hole_d = 3.2;            // 3 mm LED clearance
 rocker_w = 13.0;             // prototype cutout; measure purchased rocker
 rocker_h = 19.0;
 front_slot_w = 34.0;         // two long rounded horizontal slots near lower front
 front_slot_h = 3.2;
 // Rear reusable cloth zip-tie / Velcro pass-through brackets.
 // Two visibly vertical external brackets sit left/right of center.
 // The strap path is a lateral X-direction tunnel between the sealed rear wall
 // and raised bridge face; long side windows stay open for feeding from either side.
 rear_loop_x = 13.0;
 rear_loop_w = 8.5;            // outside bracket width in X
 rear_loop_h = 50.0;           // outside bracket height in Z
 rear_loop_z = case_h/2;
 rear_loop_gap_y = 3.8;        // usable strap-thickness clearance behind raised bridge
 rear_loop_face_t = 1.4;       // low-profile outer bridge skin
 rear_loop_y = rear_loop_gap_y + rear_loop_face_t;
 rear_loop_anchor_h = 5.0;     // top/bottom weld pads; side window remains long vertically
 rear_loop_side_window_h = rear_loop_h - 2*rear_loop_anchor_h;
 // USB power connector placeholder cutouts
 usb_c_cutout_w = 10.5;        // bottom USB-C female inlet visible opening, X width
 usb_c_cutout_d = 4.5;         // bottom USB-C female inlet visible opening, Y/front-back
 usb_c_recess_w = 18.0;        // shallow underside panel-mount/breakout recess
 usb_c_recess_d = 10.0;
 usb_c_y = -7.5;               // close to front/service side but clear of screw bosses/lower slots
 usb_a_cutout_d = 16.0;        // side USB-A female opening, Y/front-back dimension
 usb_a_cutout_h = 8.0;         // side USB-A female opening, Z height
 usb_a_z = 26.0;               // mid/lower right side, clear of front lid screws/strap bridges
 usb_a_y = 2.0;
 // Left-side antenna lead / IPEX-U.FL pigtail connector placeholder.
 // Opposite the right-side USB-A port and cut fully through the left wall into the cavity.
 ipex_hole_d = 5.0;            // prototype circular clearance; measure final pigtail/bulkhead
 ipex_recess_d = 8.5;          // shallow exterior visual/seat recess, not retention geometry
 ipex_recess_depth = 0.9;
 ipex_z = usb_a_z;
 ipex_y = usb_a_y;
 // ----- Utility geometry -----
 module rounded_box(size=[10,10,10], r=2, center_xy=true) {
    // Rounded in XY, straight in Z.
    linear_extrude(height=size[2])
        offset(r=r)
            square([size[0]-2*r, size[1]-2*r], center=center_xy);
 }
 module xz_rounded_prism(w, d, h, r=2) {
    // Rounded rectangle in the visible X/Z plane, extruded through Y.
    rotate([-90,0,0])
        linear_extrude(height=d, center=true)
            offset(r=r)
                square([w-2*r, h-2*r], center=true);
 }
 module yz_rounded_prism(d, x, h, r=2) {
    // Rounded rectangle in the visible Y/Z plane, extruded through X.
    // First argument maps to global Y, third argument maps to global Z.
    rotate([0,90,0])
        linear_extrude(height=x, center=true)
            offset(r=r)
                square([h-2*r, d-2*r], center=true);
 }
 module y_cylinder(d, h, center=true) {
    rotate([90,0,0]) cylinder(d=d, h=h, center=center);
 }
 module x_cylinder(d, h, center=true) {
    rotate([0,90,0]) cylinder(d=d, h=h, center=center);
 }
 module screw_boss(x, z) {
    translate([x, -case_d/2 + front_recess_d + boss_len/2, z])
        difference() {
            y_cylinder(d=boss_d, h=boss_len);
            y_cylinder(d=screw_d, h=boss_len + 0.8);
        }
 }
 module rear_zip_tie_loop(xc) {
    // Vertical external belt-loop bracket for reusable cloth zip ties/Velcro.
    // The bracket silhouette remains vertical, but the real strap tunnel runs
    // laterally in X through the long side windows, behind the raised bridge face.
    // Top/bottom pads weld the bridge to the shell; no cut reaches the rear wall.
    loop_overlap_y = 0.75;
    pad_r = 1.15;
    bridge_y_center = case_d/2 + rear_loop_gap_y + rear_loop_face_t/2;
    pad_y_center = case_d/2 + rear_loop_y/2 - loop_overlap_y;
    pad_z_offset = rear_loop_h/2 - rear_loop_anchor_h/2;
    union() {
        // Raised vertical bridge face: visually preserves the requested vertical
        // rear brackets while spanning the side-feed tunnel externally.
        translate([xc, bridge_y_center, rear_loop_z])
            xz_rounded_prism(rear_loop_w, rear_loop_face_t, rear_loop_h, r=1.6);
        // Top and bottom anchor pads close the old top-to-bottom feed direction
        // and tie the raised face back into the rear wall without opening the case.
        for (zoff = [-pad_z_offset, pad_z_offset])
            translate([xc, pad_y_center, rear_loop_z + zoff])
                xz_rounded_prism(rear_loop_w, rear_loop_y, rear_loop_anchor_h, r=pad_r);
    }
 }
 // ----- Printable body -----
 module camera_node_body_v4() {
    difference() {
        union() {
            difference() {
                union() {
                    // Upright outer shell with softened appliance-like corners.
                    rounded_box([case_w, case_d, case_h], r=corner_r);
                    // Rear cloth zip-tie / Velcro side-feed brackets kept flat/quiet.
                    rear_zip_tie_loop(-rear_loop_x);
                    rear_zip_tie_loop( rear_loop_x);
                }
                // Full-height front recessed lid pocket, like the green reference panel.
                translate([0, -case_d/2 + front_recess_d/2, case_h/2])
                    cube([lid_w + lid_clearance, front_recess_d + 0.4, lid_h + lid_clearance], center=true);
                // Through service opening behind the lid, leaving a strong inset frame.
                service_depth = front_recess_d + wall + 2.0;
                translate([0, -case_d/2 + service_depth/2, case_h/2])
                    xz_rounded_prism(service_opening_w, service_depth + 0.4, service_opening_h, r=2.0);
                // Interior electronics cavity: ESP32-C3 Super Mini + ESP-01S plus wiring/service clearance.
                cavity_d = case_d - front_recess_d - 2*wall;
                translate([0, -case_d/2 + front_recess_d + wall + cavity_d/2, case_h/2])
                    cube([case_w - 2*wall, cavity_d, case_h - 2*wall], center=true);
                // Bottom USB-C female power inlet: shallow underside recess plus
                // rounded through-slot for a flush/panel-mount breakout placeholder.
                translate([0, usb_c_y, -0.35])
                    rounded_box([usb_c_recess_w, usb_c_recess_d, 0.9], r=1.5);
                translate([0, usb_c_y, -0.2])
                    rounded_box([usb_c_cutout_w, usb_c_cutout_d, wall + 1.2], r=1.6);
                // Right-side USB-A female passthrough power port for the GoPro.
                translate([case_w/2 - 0.10, usb_a_y, usb_a_z])
                    yz_rounded_prism(usb_a_cutout_d, wall + 2.8, usb_a_cutout_h, r=0.9);
                // Left-side IPEX/U.FL antenna pigtail connector/lead clearance.
                // Through-hole intentionally extends past the inner wall so it opens to the cavity.
                translate([-case_w/2 - 0.10, ipex_y, ipex_z])
                    x_cylinder(d=ipex_hole_d, h=wall + 3.0);
                // Shallow exterior circular recess marks/relieves the antenna exit area.
                translate([-case_w/2 + ipex_recess_depth/2 - 0.05, ipex_y, ipex_z])
                    x_cylinder(d=ipex_recess_d, h=ipex_recess_depth + 0.2);
            }
            // Four protected screw bosses are added after shell hollowing so the
            // electronics cavity cannot cut away the receiving material.
            screw_x = lid_w/2 - 5.0;
            screw_z_low = (case_h - lid_h)/2 + 5.0;
            screw_z_high = case_h - screw_z_low;
            screw_boss(-screw_x, screw_z_low);
            screw_boss( screw_x, screw_z_low);
            screw_boss(-screw_x, screw_z_high);
            screw_boss( screw_x, screw_z_high);
        }
        // Final body-level pilot holes cut through the front frame into the protected bosses.
        screw_x = lid_w/2 - 5.0;
        screw_z_low = (case_h - lid_h)/2 + 5.0;
        screw_z_high = case_h - screw_z_low;
        for (x=[-screw_x, screw_x], z=[screw_z_low, screw_z_high])
            translate([x, -case_d/2 + front_recess_d + boss_len/2, z])
                y_cylinder(d=screw_d, h=boss_len + front_recess_d + 4.0);
    }
 }
 // ----- Printable front service lid / status panel -----
 module camera_node_lid_v4() {
    panel_through_d = lid_t + lid_lip_t + 2.4;
    panel_through_y = 0.25;
    difference() {
        union() {
            // Visible full-height flush panel; restrained and not a busy slab.
            rounded_box([lid_w, lid_t, lid_h], r=0.65);
            // Rear locating lip fits inside the large service opening.
            translate([0, lid_t/2 + lid_lip_t/2 - 0.2, lid_h/2])
                xz_rounded_prism(service_opening_w - 0.8, lid_lip_t, service_opening_h - 0.8, r=1.5);
        }
        // OLED window and shallow black-bezel-style recess near the top.
        translate([0, -lid_t/2 + 0.35, oled_z])
            xz_rounded_prism(oled_bezel_w, 0.9, oled_bezel_h, r=1.3);
        translate([0, panel_through_y, oled_z])
            xz_rounded_prism(oled_window_w, panel_through_d, oled_window_h, r=0.5);
        // Subtle secondary indicators flanking the rocker, below the OLED bezel.
        translate([-15.0, panel_through_y, 33.0]) y_cylinder(d=led_hole_d, h=panel_through_d);
        translate([ 15.0, panel_through_y, 33.0]) y_cylinder(d=led_hole_d, h=panel_through_d);
        // Small rocker lower on the panel, offset away from the OLED, screws, and slots.
        translate([0, panel_through_y, 33.0])
            xz_rounded_prism(rocker_w, panel_through_d, rocker_h, r=0.8);
        // Two long rounded horizontal slots near the lower front, matching the reference.
        translate([0, panel_through_y, 17.0])
            xz_rounded_prism(front_slot_w, panel_through_d, front_slot_h, r=front_slot_h/2 - 0.15);
        translate([0, panel_through_y, 11.0])
            xz_rounded_prism(front_slot_w, panel_through_d, front_slot_h, r=front_slot_h/2 - 0.15);
        // Screw clearance/counterbore holes.
        screw_x = lid_w/2 - 5.0;
        screw_z_low = 5.0;
        screw_z_high = lid_h - screw_z_low;
        for (x=[-screw_x, screw_x], z=[screw_z_low, screw_z_high]) {
            translate([x, panel_through_y, z]) y_cylinder(d=screw_d + 0.4, h=panel_through_d);
            translate([x, -lid_t/2 + 0.55, z]) y_cylinder(d=screw_head_d, h=1.3);
        }
    }
 }
 // ----- Non-print preview assembly -----
 module camera_node_preview_v4(show_lid=true) {
    color("lightgray") camera_node_body_v4();
    if (show_lid)
        translate([0, -case_d/2 + lid_t/2 + 0.03, (case_h - lid_h)/2])
            color("gainsboro") camera_node_lid_v4();
    // Dark OLED bezel/window cue for visual review only (not part of exported lid STL when rendering lid).
    if (show_lid)
        translate([0, -case_d/2 - 0.08, (case_h - lid_h)/2 + oled_z])
            color("black") xz_rounded_prism(oled_bezel_w, 0.6, oled_bezel_h, r=1.3);
    // Internal board/connector volume guides (not printed): ESP modules and USB connector envelopes.
    color([0,0.45,0,0.35]) translate([-9, -1, 26]) cube([22.5, 18, 4], center=true);
    color([0,0.2,0.8,0.35]) translate([9, -1, 45]) cube([24.7, 14.3, 12], center=true);
    color([0.1,0.1,0.1,0.35]) translate([0, usb_c_y, 3.8]) cube([16, 9, 5], center=true);
    color([0.1,0.1,0.1,0.35]) translate([case_w/2 - 5.5, usb_a_y, usb_a_z]) cube([11, usb_a_cutout_d + 2, usb_a_cutout_h + 2], center=true);
    color([0.9,0.7,0.1,0.45]) translate([-case_w/2 - 1.8, ipex_y, ipex_z]) x_cylinder(d=ipex_hole_d, h=8.0);
 }
 // Non-print review layout: separates the body and front lid while keeping both
 // front faces oriented toward -Y. Use this STL when checking that the screen,
 // LED, rocker, USB connector, and lower-slot cutouts are visible in a slicer.
 module camera_node_front_review_v4() {
    translate([-34, 0, 0]) rotate([0,0,-18]) color("lightgray") camera_node_body_v4();
    translate([34, -case_d/2 + lid_t/2 + 0.03, (case_h - lid_h)/2])
        color("gainsboro") camera_node_lid_v4();
 }
 // Select part to render from OpenSCAD CLI with: -D 'part="body"'
 part = "preview"; // "body", "lid", "preview", or "front_review"
 if (part == "body") {
    camera_node_body_v4();
 } else if (part == "lid") {
    camera_node_lid_v4();
 } else if (part == "front_review") {
    camera_node_front_review_v4();
 } else {
    camera_node_preview_v4();
 }