hardware/DESIGN_PIPELINE.md

@@ -25,7 +25,7 @@
 - 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, and right-side USB-A female passthrough power port for the GoPro.
 - 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 pass-through loops, not a clamp/dovetail.
+- 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.
@@ -34,7 +34,7 @@
   - 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, and two vertical external rear zip-tie/Velcro pass-through loops to resist rotation on a stand.
+- 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, 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.
@@ -73,11 +73,11 @@ BAT 87%  LINK OK
   - pilot diameter, screw length, and head/counterbore diameter.
 - Mounting straps:
   - cloth zip-tie / Velcro width and thickness.
-  - prototype rear loop tunnel: ~6.4 mm usable strap width × ~3.8 mm strap-thickness clearance, with each visible vertical bracket ~8.5 mm wide × 50 mm tall.
+  - 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 loop edges need larger radii or TPU/silicone sleeve protection.
+  - whether rear vertical bracket/window edges need larger radii or TPU/silicone sleeve protection.
 - Printability:
-  - rear vertical zip-tie loop side-pad/bridge strength and whether the top-to-bottom pass-through tunnels print cleanly without supports.
+  - 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 cutout edge quality, wall strength, and connector retention/strain relief.
@@ -91,7 +91,7 @@ openscad -o /tmp/camera-node-case-v4-preview.stl hardware/case/camera-node-case-
 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 guide volumes by design. A rear-loop sanity check confirms both vertical brackets have clear non-solid pass-through tunnel volumes behind the raised bridges.
+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 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.
 
 Or with the main parametric selector:
 

hardware/README.md

@@ -43,7 +43,7 @@ Each camera node is two ESP boards in a small upright stand-mounted case. The ca
 | 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 pass-through loops |
+| 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:** roughly ~$25–$35 plus GoPro and power bank, depending on display/switch choice.
 
@@ -62,7 +62,7 @@ The current v4 CAD replaces the rejected wide/low electronics-box layout with a
    - 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 loops** — two low-profile external belt-loop brackets, one left and one right of center, with real top-to-bottom tunnels behind the raised bridges for feeding reusable cloth zip ties / Velcro straps.
+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.
 
 ### Export wrappers
@@ -98,9 +98,9 @@ openscad -D 'part="front_review"' -o hardware/case/camera-node-case-v4-front-rev
 
 - **Material:** PETG preferred for heat/outdoor use and strap-tab durability.
 - **Layer:** 0.2 mm typical.
-- **Infill:** 20% gyroid minimum; 30%+ recommended around rear vertical zip-tie loop side pads/bridges.
-- **Supports:** likely minimal/none depending on orientation; verify the vertical rear pass-through tunnels remain open and check USB-C/USB-A port cutouts in slicer.
-- **Post-processing:** fit 4 lid screws; deburr OLED/LED/switch cutouts; clear any stringing inside the rear pass-through tunnels; soften strap-contact edges if the printed radius is too sharp for cloth ties.
+- **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 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
 
@@ -163,7 +163,7 @@ The ESP8266/ESP-01S and GoPro talk over Wi-Fi. The only cable to the GoPro is US
 ## Field Setup
 
 1. Mount GoPro on tripod/stand.
-2. Feed two reusable cloth zip ties / Velcro straps through the rear vertical pass-through loops from top to bottom.
+2. Feed two reusable cloth zip ties / Velcro straps laterally through the long side openings behind the rear vertical brackets.
 3. Strap the case to a tripod/stand leg; use both strap paths to resist rotation.
 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. Toggle rocker switch on.
@@ -177,13 +177,13 @@ Prototype v4 nominal CAD dimensions:
 | Part / feature | W × D × H (mm) |
 |---|---|
 | Case shell external | ~56 × 36 × 82 |
-| Case with rear zip-tie loops | ~56 × 40.5 × 82 |
+| Case with rear zip-tie brackets | ~56 × 41.2 × 82 |
 | Front recessed lid | visible panel ~48 × 2 × 74; total with locating lip ~48 × 3 × 74 |
 | OLED visible window assumption | ~31 × 16 |
 | 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 loops | two external pass-through brackets, each ~8.5 mm wide × 50 mm tall; usable tunnel ~6.4 mm strap width × ~3.8 mm strap-thickness clearance, open top/bottom for feeding |
+| 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.

hardware/case/camera-node-case-v4.scad

@@ -1,7 +1,7 @@
 // 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 zip-tie pass-through loops are on the +Y face.
+// 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.
@@ -50,10 +50,10 @@ 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 loops.
-// Two visibly vertical external belt-loop brackets sit left/right of center.
-// The strap path is the real non-solid tunnel between rear wall and raised bridge;
-// it stays outside the electronics cavity and is open at the top/bottom for feeding.
+// 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
@@ -61,8 +61,8 @@ 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_usable_w = 6.4;     // usable strap width through each vertical loop
-rear_loop_side_pad = (rear_loop_w - rear_loop_usable_w) / 2;
+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
@@ -114,25 +114,26 @@ module screw_boss(x, z) {
 
 module rear_zip_tie_loop(xc) {
     // Vertical external belt-loop bracket for reusable cloth zip ties/Velcro.
-    // The central void is a real strap tunnel: rear wall -> air gap -> raised
-    // outer bridge face. Side pads weld the bridge to the shell while keeping
-    // the electronics cavity sealed; the tunnel is open at top and bottom.
+    // 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;
-    tunnel_extra_y = 0.35;
-    tunnel_clear_z = rear_loop_h + 0.8;
+    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;
 
-    translate([xc, case_d/2 + rear_loop_y/2 - loop_overlap_y, rear_loop_z])
-        difference() {
-            xz_rounded_prism(rear_loop_w, rear_loop_y, rear_loop_h, r=1.6);
+    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);
 
-            // Real vertical feed-through gap behind the raised bridge.  Starts
-            // just outside the rear wall, so it cannot cut into the enclosure.
-            translate([0,
-                       -rear_loop_y/2 + loop_overlap_y + rear_loop_gap_y/2 + 0.08,
-                       0])
-                cube([rear_loop_usable_w,
-                      rear_loop_gap_y + tunnel_extra_y,
-                      tunnel_clear_z], center=true);
+        // 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);
     }
 }
 
@@ -145,7 +146,7 @@ module camera_node_body_v4() {
                     // Upright outer shell with softened appliance-like corners.
                     rounded_box([case_w, case_d, case_h], r=corner_r);
 
-                    // Rear cloth zip-tie / Velcro pass-through loops kept flat/quiet.
+                    // 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);
                 }