remote-rig/hardware/DESIGN_PIPELINE.md

# 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`
- `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:** 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.
- 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.