""" Coral Eye - a privacy-first AI camera enclosure for the Synaptics Coralboard SL. Parametric source (build123d 0.8). All coordinates are in the board frame of the official Coralboard SL reference STEP (Printables @Google_Coral, Apache-2.0): x -> along the board, left to right (USB-C on the right) y -> from the front edge (USB / buttons) to the back edge (GPIO header) z -> out of the component side; the PCB top surface is z = 0 The device stands with the board vertical: board y is "up", board z is "towards the viewer". The camera module (the kit's Arducam OV5647, UC-346 board) sits in front of the SoM. Its flex cable (the ~55 mm one from the kit) leaves the camera's bottom edge, U-turns and runs behind the camera into the CSI socket - the same single fold as in Google's own sensor-HAT assembly. """ from build123d import * import math import os HERE = os.path.dirname(os.path.abspath(__file__)) OUT_DIR = os.path.normpath(os.path.join(HERE, "..", "out")) # -------------------------------------------------------------------------- # Board reference (measured from Synaptics_CoralBoard_SL.step) # -------------------------------------------------------------------------- PCB_X0, PCB_X1 = -3.80, 69.20 PCB_Y0, PCB_Y1 = -2.025, 55.975 PCB_T = 1.618 HOLES = [(-0.3, 4.47), (-0.3, 52.48), (64.7, 4.47), (64.7, 52.48)] # M3, d3.2 # Connectors that face the walls (centre / extents taken from the STEP) USER_BTN_X, RESET_BTN_X, BTN_Z = 6.70, 42.92, 0.95 # side-push buttons, stems end at y = -3.0 BTN_STEM_Y = -3.0 LEDS = [(36.25, 0.0), (38.13, 0.0), (47.63, 0.0)] # 0603 top-view LEDs, top at z = 0.9 # -------------------------------------------------------------------------- # Enclosure envelope # -------------------------------------------------------------------------- WALL = 2.0 CAV_X0, CAV_X1 = -4.3, 69.7 # 0.5 mm around the PCB CAV_Y0, CAV_Y1 = -3.6, 56.5 # USB shields stick out to y = -3.25 OUT_X0, OUT_X1 = CAV_X0 - WALL, CAV_X1 + WALL OUT_Y0, OUT_Y1 = CAV_Y0 - WALL, CAV_Y1 + WALL R_OUT = 6.0 R_IN = R_OUT - WALL Z_BACK = -6.2 # rear outer surface (bed side of the body) Z_FLOOR = -4.2 # inner floor: clears bumpers (-3.78), DSI socket (-3.50), pins (-3.34) Z_SPLIT = 9.2 # face inner surface: clears header pins (8.59) Z_RIM = Z_SPLIT - 0.2 # body rim stays 0.2 mm short: the pillars, not the rim, set the closure FACE_T = 4.0 Z_FRONT = Z_SPLIT + FACE_T CX, CY = (OUT_X0 + OUT_X1) / 2, (OUT_Y0 + OUT_Y1) / 2 W_OUT, H_OUT = OUT_X1 - OUT_X0, OUT_Y1 - OUT_Y0 CAV_CX, CAV_CY = (CAV_X0 + CAV_X1) / 2, (CAV_Y0 + CAV_Y1) / 2 W_CAV, H_CAV = CAV_X1 - CAV_X0, CAV_Y1 - CAV_Y0 # -------------------------------------------------------------------------- # Camera module (Arducam OV5647 "UC-346", Raspberry Pi camera v1.3 footprint) # -------------------------------------------------------------------------- CAM_W, CAM_H, CAM_T = 25.0, 24.0, 1.0 CAM_X0 = 32.9 # left edge; lens column lines up with the CSI socket CAM_Y_TOP = 34.5 # edge opposite the flex connector (just below mikroBUS) CAM_Z_FRONT = 5.8 # PCB front face; the back sits 2.2 mm above the SoM CAM_HOLES_UV = [(2.0, 2.0), (23.0, 2.0), (2.0, 14.5), (23.0, 14.5)] # from top-left, v down CAM_PILOT_D = 1.45 # kit's M1.6 screws, or M2 x 4-5 self-tapping LENS_UV = (12.5, 14.2) # lens centre: Raspberry Pi camera drawing and Google's kit photo agree LENS_BLOCK = 8.6 # square lens holder LENS_BLOCK_H = 5.0 LENS_POCKET = (12.4, 16.0) # generous: +-1.9 mm in x, +-3.7 mm in y around the estimate LENS_HEADROOM = 0.8 def cam_xy(u, v): return CAM_X0 + u, CAM_Y_TOP - v LENS_X, LENS_Y = cam_xy(*LENS_UV) EYE_D = 11.6 # Lens: the twist shutter module (shutter.py) is screwed to the face with two M2 screws # at +-LENS_SCREW_DX; the face only carries their blind pilot holes. LENS_SCREW_DX = 13.0 # 2.5 mm from the camera posts: no clash with any camera screw LENS_SCREW_PILOT = (1.6, 3.8) # diameter, depth from the front (M2 x 6 reaches 3.4) LENS_MODULE_D = 38.0 # twist ring diameter: sets the wordmark's margins # Lite option without moving parts: a flat ring glued onto the face. Both mating # surfaces are first layers on the bed, so there is no seat, bridge or membrane; # the privacy cap, pushed through the ring into the eye, centres it while the glue sets. RING_D = 36.0 RING_PROUD = 1.8 # ring height above the face RING_BORE_H = 0.5 # straight part of the bore, where the cap's ribs grip WORDMARK = "CORAL EYE" WORDMARK_SIZE = 6.0 # strokes >= 0.8 mm: they survive the first layer on a 0.4 mm nozzle # -------------------------------------------------------------------------- # Rear mount rail (female dovetail in the back, open at the bottom edge) # -------------------------------------------------------------------------- RAIL_CX = CX RAIL_W_OPEN = 16.0 # width at the back surface RAIL_DEPTH = 2.0 RAIL_W_IN = RAIL_W_OPEN + 2 * RAIL_DEPTH # 45 deg undercut -> 20 mm bridged ceiling RAIL_Y_STOP = 26.0 RAIL_CLEAR = 0.2 # per side, for the male tongues RAIL_TOP_CLEAR = 0.7 # tongue top stays this far under the (bridged) ceiling, even if it sags a little RAIL_LATCH_Y = 10.5 # detent groove: low enough that a latch finger fits on either side of it # (root below for mounts printed upright, root above for mounts printed upside down) LATCH_H = 1.3 # wedge height on the tongue (0.6 mm into the ceiling, 0.4 mm beyond the play) LATCH_ENTRY = 45.0 # entry face angle (deg from the tongue surface) LATCH_HOLD = 55.0 # retaining face angle: holds 5-12 N, yet a firm pull releases it GROOVE_D = 1.0 # detent groove depth in the rail ceiling # Port bay in the bottom wall (Qwiic + USB-A): open up to the rim, the face closes it, # so a USB-A overmold up to ~10 mm thick fits (the receptacle's centre is at z = 3.84) BAY_X0, BAY_X1, BAY_Z0 = 11.5, 34.0, -1.7 # USER button plunger (captured between the wall and the board's button stem) PLUNGER_HOLE_D = 3.2 PLUNGER_D = 2.8 PLUNGER_FLANGE = (4.6, 0.45) # diameter, thickness PLUNGER_PROUD = 0.7 # ========================================================================== # helpers # ========================================================================== def rrect_prism(cx, cy, w, h, r, z0, z1): """Rounded rectangle in XY, extruded between z0 and z1.""" return Pos(cx, cy, z0) * extrude(RectangleRounded(w, h, r), amount=z1 - z0) def cyl(x, y, z0, z1, d): return Pos(x, y, z0) * Cylinder(radius=d / 2, height=z1 - z0, align=(Align.CENTER, Align.CENTER, Align.MIN)) def _rr(w, h, r): r = min(r, w / 2 - 0.01, h / 2 - 0.01) return RectangleRounded(w, h, r) if r > 0.05 else Rectangle(w, h) def cut_y(x0, x1, z0, z1, r, y_from, y_to): """Rounded-rectangle hole (in the XZ plane) running along y from y_from to y_to.""" sk = Plane.XZ.offset(-y_from) * Pos((x0 + x1) / 2, (z0 + z1) / 2) * _rr(x1 - x0, z1 - z0, r) return extrude(sk, amount=y_from - y_to) def cut_x(y0, y1, z0, z1, r, x_from, x_to): """Rounded-rectangle hole (in the YZ plane) running along x from x_from to x_to.""" sk = Plane.YZ.offset(x_from) * Pos((y0 + y1) / 2, (z0 + z1) / 2) * _rr(y1 - y0, z1 - z0, r) return extrude(sk, amount=x_to - x_from) def funnel_y(x0, x1, z0, z1, r, y_face, depth, grow): """45-degree lead-in around an opening on a wall whose outer face is at y = y_face (outside is -y).""" w, h = x1 - x0, z1 - z0 outer = Plane.XZ.offset(-(y_face - 0.01)) * Pos((x0 + x1) / 2, (z0 + z1) / 2) * _rr(w + 2 * grow, h + 2 * grow, r + grow) inner = Plane.XZ.offset(-(y_face + depth)) * Pos((x0 + x1) / 2, (z0 + z1) / 2) * _rr(w, h, r) return loft([outer, inner]) def funnel_x(y0, y1, z0, z1, r, x_face, depth, grow): """45-degree lead-in around an opening on the right wall (outer face at x = x_face, outside is +x).""" w, h = y1 - y0, z1 - z0 outer = Plane.YZ.offset(x_face + 0.01) * Pos((y0 + y1) / 2, (z0 + z1) / 2) * _rr(w + 2 * grow, h + 2 * grow, r + grow) inner = Plane.YZ.offset(x_face - depth) * Pos((y0 + y1) / 2, (z0 + z1) / 2) * _rr(w, h, r) return loft([outer, inner]) def teardrop_y(x, z, d, y_from, y_to): """Horizontal round hole along y with a 45-degree roof (towards +z), so it prints without sagging.""" r = d / 2 k = r / math.sqrt(2) hole = Pos(x, (y_from + y_to) / 2, z) * Rot(90, 0, 0) * Cylinder(radius=r, height=abs(y_from - y_to)) roof = Plane.XZ.offset(-y_from) * Polygon((x - k, z + k), (x + k, z + k), (x, z + r * math.sqrt(2)), align=None) return hole + extrude(roof, amount=y_from - y_to) def dovetail_prism(w_narrow, w_wide, depth, z_narrow, y0, y1, cx, toward_minus_z=False): """Trapezoid (narrow at z_narrow, wide at z_narrow +/- depth) extruded along y.""" zw = z_narrow - depth if toward_minus_z else z_narrow + depth pts = [(cx - w_narrow / 2, z_narrow), (cx + w_narrow / 2, z_narrow), (cx + w_wide / 2, zw), (cx - w_wide / 2, zw)] sk = Plane.XZ.offset(-y0) * Polygon(*pts, align=None) return extrude(sk, amount=y0 - y1) def ridge_x(xc, y_apex, z0, height, width, entry_deg, hold_deg, up=True): """Asymmetric ridge running along x: apex at y_apex, rising `height` from the plane z = z0. The +y face has the entry angle, the -y face the holding angle (both from the plane).""" s = 1 if up else -1 pts = [(y_apex - height / math.tan(math.radians(hold_deg)), z0), (y_apex + height / math.tan(math.radians(entry_deg)), z0), (y_apex, z0 + s * height)] sk = Plane.YZ.offset(xc - width / 2) * Polygon(*pts, align=None) return extrude(sk, amount=width) # ========================================================================== # BODY (rear shell) - printed back-down, no supports # ========================================================================== def make_body(): body = rrect_prism(CX, CY, W_OUT, H_OUT, R_OUT, Z_BACK, Z_RIM) body = chamfer(body.edges().group_by(Axis.Z)[0], length=1.0) # back edge body = chamfer(body.edges().group_by(Axis.Z)[-1], length=0.5) # rim: forms the seam groove body -= rrect_prism(CAV_CX, CAV_CY, W_CAV, H_CAV, R_IN, Z_FLOOR, Z_SPLIT + 1) # thicker floor under the mount rail, with a pocket under the one USB-A shield tab # that comes through the PCB above it (x 31.95-32.25, y 6.40-7.94, down to z -2.16) pad_w = RAIL_W_IN + 4.0 pad_top = -2.45 body += rrect_prism(RAIL_CX, (CAV_Y0 + RAIL_Y_STOP + 2.0) / 2, pad_w, RAIL_Y_STOP + 2.0 - CAV_Y0, 1.0, Z_FLOOR - 0.01, pad_top) body -= rrect_prism(32.1, 7.17, 3.2, 3.6, 0.8, -3.1, pad_top + 0.5) # board standoffs: wide foot (below the rubber bumpers) + column up to the PCB for i, (hx, hy) in enumerate(HOLES): col_d = 5.4 if i == 1 else 6.0 # top-left one clears the bumper next to it body += cyl(hx, hy, Z_FLOOR - 0.01, -3.95, 8.4) # 8.4: merges into the wall, no tangency body += cyl(hx, hy, Z_FLOOR - 0.01, -PCB_T, col_d) body -= cyl(hx, hy, Z_BACK - 1, Z_SPLIT, 3.4) # M3 clearance # button-head counterbore, ending 0.2 mm inside the floor: printed back-down, the column # above then starts on solid floor instead of in mid-air (head sits 0.15 mm below the back) body -= cyl(hx, hy, Z_BACK - 1, Z_FLOOR - 0.2, 6.2) # ---- bottom wall (board front edge) ---- yo, yi = OUT_Y0 - 1.0, CAV_Y0 + 1.0 # one bay for Qwiic + USB-A, open up to the rim (no thin strip above it): the face closes it bay = (BAY_X0, BAY_X1, BAY_Z0, Z_RIM + 1.0, 1.5) body -= cut_y(bay[0], bay[1], bay[2], bay[3], bay[4], yo, yi) body -= funnel_y(bay[0], bay[1], bay[2], bay[3], bay[4], OUT_Y0, 0.8, 0.8) usbc = (49.28, 62.28, -2.48, 4.92, 1.5) # USB-C: admits rounded-rectangle overmolds body -= cut_y(usbc[0], usbc[1], usbc[2], usbc[3], usbc[4], yo, yi) body -= funnel_y(usbc[0], usbc[1], usbc[2], usbc[3], usbc[4], OUT_Y0, 0.6, 0.6) body -= Pos(RESET_BTN_X, 0, BTN_Z) * Rot(90, 0, 0) * Cylinder(radius=0.9, height=20) # reset pinhole body -= Pos(RESET_BTN_X, OUT_Y0, BTN_Z) * Rot(-90, 0, 0) * Cone(bottom_radius=1.9, top_radius=0.9, height=1.0, align=(Align.CENTER, Align.CENTER, Align.MIN)) for vx in (64.8,): # small vent right of USB-C body -= cut_y(vx - 0.8, vx + 0.8, -2.5, 5.0, 0.79, yo, yi) # USER button: hole for the captured printed plunger (teardrop: the roof doesn't sag onto the shaft) body -= teardrop_y(USER_BTN_X, BTN_Z, PLUNGER_HOLE_D, yi, yo) body -= Pos(USER_BTN_X, OUT_Y0, BTN_Z) * Rot(-90, 0, 0) * Cone(bottom_radius=PLUNGER_HOLE_D / 2 + 0.6, top_radius=PLUNGER_HOLE_D / 2, height=0.6, align=(Align.CENTER, Align.CENTER, Align.MIN)) # ---- left wall: microSD slot + vertical finger scoop (keeps a 0.8 mm wall) ---- xo, xi = OUT_X0 - 1.0, CAV_X0 + 1.0 body -= cut_x(19.6, 31.6, -0.35, 2.05, 0.6, xo, xi) body -= cyl(OUT_X0 - 3.8, 25.6, -2.2, 3.9, 10.0) # ---- right wall: I2S2 (JST-SH 7) and battery (JST-PH 2), with lead-ins ---- xo, xi = OUT_X1 + 1.0, CAV_X1 - 1.0 i2s = (19.2, 28.8, -0.30, 3.30, 0.8) bat = (9.6, 16.1, -0.30, 6.50, 1.0) for o in (i2s, bat): body -= cut_x(o[0], o[1], o[2], o[3], o[4], xi, xo) body -= funnel_x(o[0], o[1], o[2], o[3], o[4], OUT_X1, 1.0, 1.0) # ---- top wall: chimney vents above the SoM / mikroBUS side ---- for k in range(7): vx = 37.0 + 4.0 * k body -= cut_y(vx - 0.8, vx + 0.8, -3.0, 7.0, 0.79, OUT_Y1 + 1.0, CAV_Y1 - 1.0) # ---- rear mount rail (female dovetail, open at the bottom) + detent groove ---- body -= dovetail_prism(RAIL_W_OPEN, RAIL_W_IN, RAIL_DEPTH, Z_BACK - 0.01, OUT_Y0 - 1.0, RAIL_Y_STOP, RAIL_CX) body -= dovetail_prism(RAIL_W_OPEN + 2.0, RAIL_W_OPEN, 1.0, Z_BACK - 0.01, OUT_Y0 - 1.0, OUT_Y0 + 1.0, RAIL_CX) # lead-in chamfer body -= ridge_x(RAIL_CX, RAIL_LATCH_Y, Z_BACK + RAIL_DEPTH - 0.01, GROOVE_D, 6.6, LATCH_ENTRY, LATCH_HOLD) # ---- engraved label on the back (reads correctly from behind) ---- # (strokes >= 0.8 mm, so the first layer doesn't close them) lbl = Plane(origin=(CX, 47.0, Z_BACK), x_dir=(-1, 0, 0), z_dir=(0, 0, -1)) body -= extrude(lbl * Text("CORAL EYE", font_size=9.0, font_style=FontStyle.BOLD), amount=-0.6) lbl2 = Plane(origin=(CX, 37.5, Z_BACK), x_dir=(-1, 0, 0), z_dir=(0, 0, -1)) body -= extrude(lbl2 * Text("for Coralboard SL", font_size=5.5, font_style=FontStyle.BOLD), amount=-0.6) return body def make_user_plunger(): """Captured button plunger, in assembly position. Print it flange-down.""" y_in = BTN_STEM_Y - 0.15 # 0.15 mm short of the switch stem at rest y_out = OUT_Y0 - PLUNGER_PROUD shaft = Pos(USER_BTN_X, y_out, BTN_Z) * Rot(-90, 0, 0) * Cylinder( radius=PLUNGER_D / 2, height=y_in - y_out, align=(Align.CENTER, Align.CENTER, Align.MIN)) flange = Pos(USER_BTN_X, y_in - PLUNGER_FLANGE[1], BTN_Z) * Rot(-90, 0, 0) * Cylinder( radius=PLUNGER_FLANGE[0] / 2, height=PLUNGER_FLANGE[1], align=(Align.CENTER, Align.CENTER, Align.MIN)) p = shaft + flange return fillet(p.edges().group_by(Axis.Y)[0], radius=0.5) # ========================================================================== # FACE (front plate) - printed face-down, no supports # ========================================================================== def make_face(led_windows="skin"): face = rrect_prism(CX, CY, W_OUT, H_OUT, R_OUT, Z_SPLIT, Z_FRONT) face = chamfer(face.edges().group_by(Axis.Z)[-1], length=1.0) # front edge face = chamfer(face.edges().group_by(Axis.Z)[0], length=0.5) # rim: seam groove # alignment lips that drop into the body (kept clear of mikroBUS / headers) lip_t, lip_h, cl = 1.0, 1.6, 0.15 xi0, xi1, yi0, yi1 = CAV_X0 + cl, CAV_X1 - cl, CAV_Y0 + cl, CAV_Y1 - cl z0 = Z_SPLIT - lip_h face += Pos(xi0 + lip_t / 2, 27.0, z0) * Box(lip_t, 42.0, lip_h + 0.01, align=(Align.CENTER, Align.CENTER, Align.MIN)) face += Pos(xi1 - lip_t / 2, 27.0, z0) * Box(lip_t, 42.0, lip_h + 0.01, align=(Align.CENTER, Align.CENTER, Align.MIN)) face += Pos(15.0, yi1 - lip_t / 2, z0) * Box(30.0, lip_t, lip_h + 0.01, align=(Align.CENTER, Align.CENTER, Align.MIN)) for lx0, lx1 in ((0.0, BAY_X0 - 0.5), (BAY_X1 + 0.5, 48.0)): # bottom lip, interrupted at the port bay face += Pos((lx0 + lx1) / 2, yi0 + lip_t / 2, z0) * Box(lx1 - lx0, lip_t, lip_h + 0.01, align=(Align.CENTER, Align.CENTER, Align.MIN)) # pillars clamp the PCB against the body standoffs; M3 screws come from the back for hx, hy in HOLES: face += cyl(hx, hy, 0.0, Z_SPLIT + 0.01, 6.0) face -= cyl(hx, hy, -1.0, 9.0, 2.6) # pilot for M3 self-tapping # camera: four posts for the kit's M1.6 screws for u, v in CAM_HOLES_UV: px, py = cam_xy(u, v) face += cyl(px, py, CAM_Z_FRONT, Z_SPLIT + 0.01, 4.4) face -= cyl(px, py, CAM_Z_FRONT - 1.0, CAM_Z_FRONT + 3.0, CAM_PILOT_D) # lens holder pocket (inside), generous because the lens position is estimated; # in front of it the face stays solid (1.6 mm, printed on the bed) except for the eye pocket_top = CAM_Z_FRONT + LENS_BLOCK_H + LENS_HEADROOM # 11.6 face -= rrect_prism(LENS_X, LENS_Y, LENS_POCKET[0], LENS_POCKET[1], 1.0, Z_SPLIT - 1.0, pocket_top) face -= cyl(LENS_X, LENS_Y, pocket_top - 0.1, Z_FRONT + 1.0, EYE_D) # 0.4 mm lead-in at the eye's mouth: the shutter's sleeve enters here, and this edge is the # face's first layer (elephant foot) face -= Pos(LENS_X, LENS_Y, Z_FRONT - 0.4) * Cone(bottom_radius=EYE_D / 2, top_radius=EYE_D / 2 + 0.41, height=0.41, align=(Align.CENTER, Align.CENTER, Align.MIN)) for sx in (-1, 1): # pilots for the shutter module's M2 screws face -= cyl(LENS_X + sx * LENS_SCREW_DX, LENS_Y, Z_FRONT - LENS_SCREW_PILOT[1], Z_FRONT + 1.0, LENS_SCREW_PILOT[0]) # status light bar under the lens: one light pipe over the three LEDs, # hidden behind a 0.4 mm skin (glows through light filaments) or open tube_bottom = 2.0 bx0, bx1 = LEDS[0][0] - 1.6, LEDS[2][0] + 1.6 bcx, blen = (bx0 + bx1) / 2, bx1 - bx0 wall = 0.85 face += rrect_prism(bcx, 0.0, blen + 2 * wall, 1.4 + 2 * wall, 0.69 + wall, tube_bottom, Z_SPLIT + 0.01) skin = 0.4 if led_windows == "skin" else -1.0 face -= rrect_prism(bcx, 0.0, blen, 1.4, 0.69, tube_bottom - 1.0, Z_FRONT - skin) # debossed wordmark, top-left, same margin as the lens ring has to the edges if WORDMARK: face -= wordmark_solid() return face def wordmark_solid(): """The front wordmark as a 0.6 mm solid: cut from the face, or printed as a colour inlay.""" margin = OUT_X1 - (LENS_X + LENS_MODULE_D / 2) txt = Plane.XY.offset(Z_FRONT) * Pos(OUT_X0 + margin, OUT_Y1 - margin) * Text( WORDMARK, font_size=WORDMARK_SIZE, font_style=FontStyle.BOLD, align=(Align.MIN, Align.MAX)) return extrude(txt, amount=-0.6) # ========================================================================== # LENS RING - printed back-down (flat back on the bed), glued flat onto the face # ========================================================================== def make_lens_ring(): """Revolved profile: flat back, flat outer rim, then a shallow cone (lens hood) down to the eye. The bore matches the eye of the face, so the privacy cap centres the ring.""" R, re = RING_D / 2, EYE_D / 2 prof = [(re, 0.0), (R - 0.3, 0.0), (R, 0.3), (R, RING_PROUD - 0.4), (R - 0.4, RING_PROUD), (R - 2.6, RING_PROUD), (R - 2.9, RING_PROUD - 0.3), (7.6, RING_BORE_H + 0.3), (re + 0.3, RING_BORE_H + 0.3), (re, RING_BORE_H)] ring = revolve(Plane.XZ * Polygon(*prof, align=None), axis=Axis.Z) return Pos(LENS_X, LENS_Y, Z_FRONT) * ring # ========================================================================== # Reference models used for checks and renders (not printed) # ========================================================================== def make_camera_mock(): pcb = Pos(CAM_X0 + CAM_W / 2, CAM_Y_TOP - CAM_H / 2, CAM_Z_FRONT - CAM_T) * Box( CAM_W, CAM_H, CAM_T, align=(Align.CENTER, Align.CENTER, Align.MIN)) for u, v in CAM_HOLES_UV: hx, hy = cam_xy(u, v) pcb -= cyl(hx, hy, CAM_Z_FRONT - 2, CAM_Z_FRONT + 1, 2.2) block = Pos(LENS_X, LENS_Y, CAM_Z_FRONT) * Box(LENS_BLOCK, LENS_BLOCK, LENS_BLOCK_H - 0.6, align=(Align.CENTER, Align.CENTER, Align.MIN)) barrel = cyl(LENS_X, LENS_Y, CAM_Z_FRONT + LENS_BLOCK_H - 0.6, CAM_Z_FRONT + LENS_BLOCK_H, 7.0) conn = Pos(CAM_X0 + CAM_W / 2, CAM_Y_TOP - CAM_H + 2.6, CAM_Z_FRONT - CAM_T) * Box( 20.0, 5.2, 1.3, align=(Align.CENTER, Align.CENTER, Align.MAX)) flexj2 = Pos(CAM_X0 + 13.1, CAM_Y_TOP - 2.7, CAM_Z_FRONT) * Box(8.6, 3.8, 1.0, align=(Align.CENTER, Align.CENTER, Align.MIN)) return pcb, block + barrel, conn + flexj2 def make_flex_cable(): """15-to-22 pin flex: leaves the camera downward, U-turns and runs behind the camera into the CSI socket.""" t = 0.15 w15, w22 = 16.0, 11.5 xc = 45.4 zc = CAM_Z_FRONT - CAM_T - 0.65 # mid-height of the camera connector y_conn = CAM_Y_TOP - CAM_H + 2.0 parts = [] parts.append(Pos(xc, (y_conn + 6.0) / 2, zc) * Box(w15, y_conn - 6.0, t)) r = (zc - 3.0) / 2 tube = Pos(xc, 6.0, 3.0 + r) * Rot(0, 90, 0) * (Cylinder(radius=r + t / 2, height=w15) - Cylinder(radius=r - t / 2, height=w15 + 1)) tube -= Pos(xc, 6.0 + 10, 3.0 + r) * Box(w15 + 2, 20, 20) parts.append(tube) parts.append(Pos(xc, (6.0 + 37.0) / 2, 3.0) * Box(w15, 31.0, t)) parts.append(Pos(45.4, (37.0 + 45.5) / 2, 1.0) * Box(w22, 8.5, t)) parts.append(Pos(xc, 37.0, 2.0) * Rot(-63, 0, 0) * Box(w22, 2.2, t)) return parts def export_all(): os.makedirs(OUT_DIR, exist_ok=True) body = make_body() face = make_face("skin") face_open = make_face("open") ring = make_lens_ring() plunger = make_user_plunger() tol = dict(tolerance=0.01, angular_tolerance=0.2) export_step(body, os.path.join(OUT_DIR, "CoralEye_Body.step")) export_step(face, os.path.join(OUT_DIR, "CoralEye_Face.step")) export_step(ring, os.path.join(OUT_DIR, "CoralEye_LensRing_Lite.step")) export_step(plunger, os.path.join(OUT_DIR, "CoralEye_UserButton.step")) # print orientation: body back-down, face front-down, ring front-up, plunger flange-down export_stl(Pos(0, 0, -Z_BACK) * body, os.path.join(OUT_DIR, "CoralEye_Body.stl"), **tol) flip = Pos(0, 0, Z_FRONT) * Rot(180, 0, 0) export_stl(flip * face, os.path.join(OUT_DIR, "CoralEye_Face_hidden-LEDs.stl"), **tol) export_stl(flip * face_open, os.path.join(OUT_DIR, "CoralEye_Face_open-LEDs.stl"), **tol) # two-colour option: load this together with a face STL as one object with two parts export_stl(flip * wordmark_solid(), os.path.join(OUT_DIR, "CoralEye_Face_Wordmark-Inlay.stl"), tolerance=0.005, angular_tolerance=0.1) export_stl(Pos(-LENS_X, -LENS_Y, -Z_FRONT) * ring, os.path.join(OUT_DIR, "CoralEye_LensRing_Lite.stl"), tolerance=0.005, angular_tolerance=0.1) export_stl(user_plunger_print(plunger), os.path.join(OUT_DIR, "CoralEye_UserButton.stl"), tolerance=0.005, angular_tolerance=0.1) return body, face def user_plunger_print(plunger=None): """The plunger in print orientation: axis along z, flange on the bed (used for the STL and the 3MF).""" pl = Rot(-90, 0, 0) * (plunger or make_user_plunger()) # board side (flange) goes to -z bb = pl.bounding_box() pl = Pos(-(bb.min.X + bb.max.X) / 2, -(bb.min.Y + bb.max.Y) / 2, -bb.min.Z) * pl foot = pl & Pos(0, 0, 0.2) * Box(20, 20, 0.4) assert foot and foot.volume > 3.0, "USER button is not standing on its flange" return pl def export_render_meshes(body, face, folder): """Assembly-frame meshes for the renders (not meant for printing).""" os.makedirs(folder, exist_ok=True) tol = dict(tolerance=0.01, angular_tolerance=0.15) export_stl(body, os.path.join(folder, "body.stl"), **tol) export_stl(face, os.path.join(folder, "face.stl"), **tol) export_stl(make_lens_ring(), os.path.join(folder, "ring.stl"), tolerance=0.005, angular_tolerance=0.1) export_stl(make_user_plunger(), os.path.join(folder, "plunger.stl"), tolerance=0.005, angular_tolerance=0.1) # render-only hardware: the four M3 button heads in the back counterbores heads = None for hx, hy in HOLES: h = Pos(hx, hy, Z_BACK + 0.15) * (Cylinder(radius=2.85, height=1.65, align=(Align.CENTER, Align.CENTER, Align.MAX)) - Pos(0, 0, -1.65) * Rot(0, 0, 0) * Box(1.6, 1.6, 2.0)) heads = h if heads is None else heads + h export_stl(heads, os.path.join(folder, "screws_back.stl"), tolerance=0.01, angular_tolerance=0.15) pcb, block, conn = make_camera_mock() export_stl(pcb, os.path.join(folder, "cam_pcb.stl"), **tol) export_stl(block, os.path.join(folder, "cam_lens.stl"), **tol) export_stl(conn, os.path.join(folder, "cam_conn.stl"), **tol) flex = make_flex_cable() cable = flex[0] for p in flex[1:]: cable += p export_stl(cable, os.path.join(folder, "cable.stl"), **tol) if __name__ == "__main__": import sys b, f = export_all() print("body volume %.1f cm3, face volume %.1f cm3" % (b.volume / 1000, f.volume / 1000)) print("body bbox", b.bounding_box()) print("face bbox", f.bounding_box()) if "--render-meshes" in sys.argv: export_render_meshes(b, f, os.path.normpath(os.path.join(HERE, "..", "render", "meshes")))