2026-04-30

2026-04-30

• LUME CAD validation pass: corrected the active build direction to K11 rear pod + ZHAOCAILIN top display + Arducam IMX586 front-right camera.
• Generated approval mockups in `hardware/cad/renders/approval/` and non-destructive validation STLs in `hardware/cad/exports/approval-v2/`.
• Legacy Jetson/SVPRO/port-bracket parts are no longer mandatory for the current build.
• Added a reversible symmetric Arducam variant: `ARDUCAM_LAYOUT="dual"`, renders under `approval_symmetric_*`, exports under `hardware/cad/exports/approval-symmetric/`, and notes in `LUME_SYMMETRIC_CAMERA_VARIANT.md`.
• Reviewed `ORBBEC_Datasheet_Femto-Mega1.pdf`: front window is acceptable, rear feedthrough was enlarged to 87 x 38mm, and legacy Femto mount was replaced with a bottom/side cradle that does not cover sensors.
• Added `hardware/cad/PRINT_APPROVAL_QUEUE_CURRENT.md` as the active queue: single-right Arducam is 15 final physical pieces / 19 with coupons; symmetric dual Arducam is 16 final physical pieces / 20 with coupons. Older print queue docs are stale and existing prearranged 3MFs need rebuilding before final print.
• Stamped old CAD print/planning docs as legacy or stale (`PRINT_PLAN.md`, `DIMENSIONAL_AUDIT.md`, old slicing checklists, old queue files, and `CAD_APPROVAL_PACK.md`) and added missing finalization items to the active spec: display retention, USB/power architecture, service access, hardware BOM, and thermal validation.
• Added pod service-access CAD: rear K11 port window, matching VESA-plate window, and right-side USB/service slot for Bluetooth/Sony adapter extension. Wrote `hardware/cad/LUME_WIRING_SERVICE_PLAN.md` and regenerated affected pod STLs in both approval export folders.
• Verified internet dimensions and updated K11 CAD to official GMKtec 132 x 125 x 58mm. Generated Blender approval renders and current OrcaSlicer 3MF approval plates for both single-right and symmetric Arducam variants. Added `LUME_DIMENSION_SOURCE_AUDIT.md`.
• Completed unattended 4K/128-sample Blender render run for single-right and symmetric Arducam variants. Output folders: `hardware/cad/renders/blender-approval-single-4k/`, `hardware/cad/renders/blender-approval-symmetric-4k/`; combined contact sheet: `hardware/cad/renders/blender-approval-4k-contact-sheet.png`. Computer Use access had worked earlier for OrcaSlicer, but later generic app-listing timed out, so file-based Orca/Blender automation remains the reliable route for now.
• Patched all current OrcaSlicer approval 3MFs to fix slicer warnings: added `G92 E0` to `before_layer_change_gcode`, lowered embedded inner/travel accelerations to 500, and set embedded travel acceleration limit to 1000. Backups live under `hardware/cad/print/3mf-current/.backup-before-g92/` and `.backup-before-accel-patch/`.
• Rebuilt the symmetric dual-Arducam internals plate after OrcaSlicer caught the original `02_internals_dual_arducam.3mf` placing objects off the bed. The broken original is now marked/moved under `hardware/cad/print/3mf-current/approval-symmetric/legacy-broken-layout/`; the usable project is `hardware/cad/print/3mf-current/approval-symmetric/02_internals_dual_arducam_ASA_READY.3mf`.
• Validated `02_internals_dual_arducam_ASA_READY.3mf` through Orca CLI: generated review G-code at `hardware/cad/print/gcode-review/symmetric-internals-asa-ready/plate_1.gcode` with ASA 260C/100C, 4 walls, 5 top/bottom layers, 25
• User selected the symmetric dual-Arducam version. Reopened the final patched `02_internals_dual_arducam_ASA_READY.3mf` in OrcaSlicer, confirmed visible settings in the GUI, sliced successfully with support/brim/support-interface, captured `hardware/cad/print/gcode-review/symmetric-internals-asa-ready/orca-gui-preview-final.png`, and regenerated `plate_1.gcode`. Final conservative estimate: about 8h33m total and about 123g ASA. Do not send to printer until physical layout approval.
• Continued to Plate 1 coupons: patched/opened `hardware/cad/print/3mf-current/approval-symmetric/01_coupons.3mf` for ASA review, confirmed GUI settings 4 walls / 5 top-bottom / 25
• Started Plate 3 shell-front-L validation. The STL is manifold and fits the Elegoo Neptune 4 Max bed, but the default orientation is not approved: support-heavy slice at about 1d15h59m / 439g ASA. Tested orientation variants under `hardware/cad/print/gcode-review/symmetric-shell-front-L-orientation-tests/`; best current candidate is rotate X +90 at about 1d10h49m / 385g ASA, preview `rx90/orca-gui-preview-candidate.png`. Do not print shell_front_L until support/orientation/design review is resolved.
• Re-ran shell validation for all four symmetric shell halves with the explicit Neptune 4 Max machine profile and ASA settings. Active matrix: `hardware/cad/print/gcode-review/symmetric-shell-all-orientation-tests/README.md`. Default orientations are rejected. Best supported candidates: front_L rotate X +90 (~18h38m/201g), front_R rotate X +90 (~10h56m/117g), rear_L rotate X -90 (~19h58m/217g), rear_R rotate X -90 build-plate support (~10h55m/116g). Total shells: ~60h27m and ~651g ASA. Old front-L-only orientation report is now marked superseded.
• Validated Plate 7 pod parts. Default pod batch is rejected and marked DO NOT PRINT (`hardware/cad/print/gcode-review/symmetric-pod-asa-ready/README_DO_NOT_PRINT.md`) because Orca estimated ~3d23h46m / 976g ASA. Added `hardware/cad/lume-pod-print-orientation.scad`, print-oriented pod STLs under `hardware/cad/exports/approval-symmetric-print-oriented/`, and `hardware/cad/print/settings/lume_pod_asa_process.json`. Best current pod review batch is `hardware/cad/print/gcode-review/symmetric-pod-print-oriented-light/plate_1.gcode` at ~2d3h56m / 521g ASA; still review-only and should likely be split into smaller jobs.
• Created split pod review jobs in `hardware/cad/print/gcode-review/symmetric-pod-split-jobs/`: pod top ~21h17m/214g, pod bottom ~21h6m/211g, compute sled ~6h2m/61g, VESA plate ~3h28m/36g. Created clean symlink queue at `hardware/cad/print/gcode-review/CURRENT_SYMMETRIC_REVIEW_QUEUE_2026-04-30/` so only current review files are visible together. Updated internals estimate in docs to the current G-code footer value: ~12h21m / 116g.