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LUME Hardware — CAD

> Current-doc warning, 2026-04-30: parts of this README still describe the earlier Jetson/SVPro in-bar architecture. The active build is documented in `LUME_CURRENT_BUILD_SPEC.md` and `PRINT_APPROVAL_QUEUE_CURRENT.md`: K11 rear pod, ZHAOCAILIN top display cradle, centered Femto Mega, and Arducam IMX586 auxiliary camera.

Embodied Trajectory Systems research note experiment writeup candidate score 26 .md

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LUME Hardware — CAD

Parametric OpenSCAD source for the LUME v1 soundbar enclosure.

File map

File	Purpose
`lume-config.scad`	Global dimensions, component footprints, toggles. Edit here first.
`lume-primitives.scad`	Reusable helpers: `rbox`, `cchamfer`, `hex_grille`, `slot_grille`, `lens_cutout`, `insert_boss`, `insert_boss_gusseted`, `bolt_m3_counterbore`, `rib`, `cable_clip`, `strain_relief`, `lip_tongue`/`lip_groove`.
`lume-components.scad`	Proxy volumes for Jetson, Femto Mega, UMA-8, Noctua fan, SVPRO, NeoPixel ring. Swap with vendor STEPs when available.
`lume-shell.scad`	Exterior shell. Front/rear cutouts, interior ribs, gusseted corner bolt bosses, split halves (`lume_shell_front` / `lume_shell_rear`).
`lume-internals.scad`	Jetson sled (96×96 pattern + heat-set bosses), Noctua fan shroud, thermal baffle, Femto bracket, SVPRO brackets (L+R), UMA-8 mic rail, cable backbone, port bracket anchor posts.
`lume-bezel.scad`	Separate printable front bezel insert + blank camera plug (for v1 demo rigs using only 2 cameras).
`lume-port-bracket.scad`	Rear port bracket with labeled cutouts: HDMI, USB-A ×2, Ethernet. Screws to interior-rear via 4 corner bolts.
`lume-vesa.scad`	VESA 100×100 plate or French cleat (bar-side + wall-side).
`lume-main.scad`	Top-level assembly. Shell + internals + proxies + bezel + diffuser + port bracket + VESA. Exploded view supported.
`render.sh`	Headless render pipeline.

Workflow

GUI (interactive)

bash

open /Applications/OpenSCAD.app lume-main.scad
# F5 = preview,  F6 = render (slow, for STL quality check)

Headless

bash

./render.sh preview   # all PNGs to exports/
./render.sh stl       # all STLs to exports/
./render.sh all       # both
./render.sh clean     # wipe exports/

Views (lume-main.scad)

Set `VIEW` variable or pass `-D VIEW="..."` to OpenSCAD:

`assembly` — shell ghosted, internals + components solid
`shell_only` — just the assembled shell
`print_front` / `print_rear` — isolate each half for slicer

Pass `-D EXPLODED=true` with `assembly` to offset parts along Y for exploded-view docs.

Iteration loop

1. Edit `lume-config.scad` (or any module)
2. `./render.sh preview` (fast, ~1 min total)
3. Check `exports/assembly.png` + `exports/exploded.png`
4. When fit looks right: `./render.sh stl`
5. Slice in Cura / PrusaSlicer → print

Print plan (9 printable parts)

Part	STL	Print time (est.)	Material
Shell front half	`shell_front.stl`	~24h	ASA grey
Shell rear half	`shell_rear.stl`	~20h	ASA grey
Front bezel insert	`bezel.stl`	~4h	ASA grey (or black for contrast)
Camera blank plug (v1 demo)	`cam_plug.stl`	~20min	ASA grey
Rear port bracket	`port_bracket.stl`	~1h	ASA grey
LED diffuser	export from `lume-internals.scad` `led_diffuser()`	~1h	clear PETG
VESA plate	`vesa_plate.stl`	~3h	ASA or PETG
French cleat (bar)	`cleat_bar.stl`	~3h	ASA
French cleat (wall)	`cleat_wall.stl`	~3h	ASA or PETG

All shell parts fit within the Neptune 4 Max build volume (420×420×480). Bond shell halves with M3×20 bolts through the 4 gusseted corner insert bosses. Print orientation: shell halves on their flat split face (prints open-side-up, no supports needed for interior).

Thermal airflow

Intake: passive hex-perforated slots on the bottom face (`INTAKE_X_LEFT`, `INTAKE_X_RIGHT`)
Hot zone: left 180mm of interior (Jetson + Noctua fan + PSU)
Cold zone: right 320mm (Femto Mega + UMA-8 mic + SVPRO cameras + LED ring)
Thermal baffle at `BAFFLE_X` separates zones — protects Femto IR sensor from warm air and keeps UMA-8 out of fan turbulence
Exhaust: Noctua NF-A8 pushes through the rear slot grille at `VENT_X` behind the Jetson heatsink

Material

Shell + internals: Polymaker ASA, dark grey (color "114", hex #8d8e92). Grey filament is the best sanding indicator since the shell is painted/coated post-print.
LED diffuser: clear PETG (translucent, prints cleanly, UV-stable)
Finish: filler primer → wet sand 320 → satin black spray → optional Wheeler Cerama-Coat for matte appliance feel

Heat-set inserts

All fastener bosses are sized for M3 knurled heat-set inserts (4.5mm OD, 6mm deep). Press with a soldering iron set to 220–240°C. Use the `INSERT_BOSS_OD=6.5` bosses — gusseted variants (`insert_boss_gusseted`) are used at the 4 corner locations where front/rear halves bond.

Component reference CAD (drop STEP files here)

references/
  jetson-agx-orin-devkit.step
  orbbec-femto-mega.step
  minidsp-uma8-v2.step
  noctua-nf-a8.step
  svpro-imx577.step

Once populated, swap `proxy_*` calls in `lume-components.scad` with `import()` of the real STEPs for precise fit validation.

Known design decisions (open for revision)

1. Wordmark: currently recessed 1.2mm paint-fill. Alternative: laser-etch post-print.
2. Right camera: blank plug in v1 demo (Femto Mega + left SVPRO is enough for depth + RGB overlay). Upgrade to full stereo later.
3. LED count: 24 NeoPixels (fits 52mm ID diffuser). 36 would require larger ring OD.
4. Power: DC barrel jack. Alternative: USB-C PD with Jetson PD controller board.
5. Mount: VESA 100×100 default. French cleat variant available for tool-free demo relocations.

Joinery option

The split plane can optionally use a tongue-and-groove lip (`USE_JOINERY=true` in `lume-config.scad`). Off by default — the 4 corner bolts alone are sufficient, and joinery requires careful clearance tuning per-printer. Enable once you have a calibration print to measure lip fit.

Promotion Decision

Attach run IDs, datasets, metrics, and reproduction commands.

Source Anchor

lume-commerce/hardware/cad/README.md

Detected Structure

Method · Evaluation · References · Architecture