LUME v2 twin-sensor checklist

LUME v2 twin-sensor checklist

_Comprehensive task list spanning hardware, CAD, software, calibration,
testing, packaging, manuals, and ship-blocking dependencies. Ordered by
unblock chain. Each item has owner, ETA, and verification criterion._

Phase 0 — Receive hardware (gates everything)

- [ ] Receive Bolt (Apr 27, Prime) — Mohamed acknowledges arrival, opens box,
verifies serial number, photographs port layout for cradle CAD reference.
- [ ] Receive K11 (next-day if ordered now) — Mohamed unboxes, plugs in,
verifies BIOS boot, confirms Linux installable. ETA per K11 BOM memo.
- [ ] Capture Bolt STEP file from `github.com/orbbec/OrbbecHardware`.
Drop into `hardware/cad/references/orbbec-femto-bolt.stp`. Convert to STL
via FreeCAD (FreeCAD → open .stp → export STL). Drop into
`hardware/cad/references/orbbec-femto-bolt.stl`. Add `USE_REAL_BOLT=true`
toggle in lume-config-bolt.scad.
- [ ] Caliper-measure Bolt — verify the 140×39×30mm we're using.
Reconcile with STEP. Update DIMENSIONAL-AUDIT.md confidence to ⭐.
- [ ] Caliper-measure K11 — verify 142.6×113×49.5mm. Reconcile.
- [ ] Caliper-measure Mega's Jetson hump — verify the +25mm protrusion claim.
- [ ] Reconcile Mega axis labels — physically measure Mac4's Mega
and update FEMTO_W/D/H constants if they're swapped.

Phase 1 — Sensor calibration & verification

- [ ] Run femto_intrinsics.py against Bolt to capture intrinsics JSON.
Save as `software/demo/femto_intrinsics_bolt.json`. Compare against
Mega's intrinsics — should be similar since same sensor silicon.
- [ ] Test Bolt with existing pointcloud_pub.py — invoke
`python3 pointcloud_pub.py --raw-depth --intrinsics-json femto_intrinsics_bolt.json --host [ip] --port 9700`
and verify LUMD packets flow at expected 6720/sec rate.
- [ ] Test Bolt over USB-C to K11 (when K11 arrives) — same publisher
command from K11 side instead of Mac4. Verify USB4 port is fast enough
for 1024² depth at 30fps.
- [ ] Verify Bolt depth quality matches Mega — capture same scene with
both, compare depth maps via `lume_packet_inspector.py --hex` for byte
comparison. Should be functionally identical given same Sony IMX556.

Phase 2 — CAD v2 — Bolt-bar shell

- [ ] Add lume-config-bolt.scad with overrides: LUME_DEPTH=60, FEMTO_W=140,
FEMTO_D=39, FEMTO_H=30, FEMTO_MOUNT_PITCH_X=TBD, FEMTO_MOUNT_PITCH_Z=TBD.
Inherit everything else from lume-config.scad via include.
- [ ] Refactor lume-shell.scad to parameterize against current config rather
than implicitly using the global lume-config.scad. Add config-include
hook so lume-shell-bolt.scad can drive it.
- [ ] Generate lume-shell-bolt.scad entrypoint that includes both configs
and renders the Bolt-config bar.
- [ ] Rebuild Bolt cradle module in lume-shell.scad to handle the new
camera dimensions. Bolt has different mount pattern; needs new bolt
hole positions in the cradle plate.
- [ ] Re-export 4 Bolt shell halves — sku1-bolt/shell_front_L.stl,
shell_front_R.stl, shell_rear_L.stl, shell_rear_R.stl at the new
60mm depth. Verify each fits 420×420 plate after split.
- [ ] Regenerate hero renders for the Bolt SKU using lume-tform-assembly.scad
with USE_BOLT_CONFIG=true. Drop into renders/bolt-hero/.
- [ ] Verify shell prints — run a single half (the smallest, shell_rear_R)
as a test print. ~3-4 hours ASA. Visually inspect for warp, splice fit,
Bolt cradle clearance.

Phase 3 — CAD v2 — Bolt pod (slimmer)

- [ ] Add lume-pod-bolt.scad with POD_D=100 (vs 130 for Mega-pod) since
no Mega Jetson hump to accommodate.
- [ ] Re-export 4 Bolt pod parts — sku1-bolt/pod_top.stl, pod_bottom.stl,
pod_compute_sled.stl, pod_vesa_plate.stl. Sled is unchanged (K11
same), pod_top/bottom shorter.
- [ ] Decide on pod-fillet aesthetic — current 12mm chamfer for Mega-bar.
Bolt-bar's slimmer profile could justify reducing to 6-8mm for visual
tightness. Render both, pick.

Phase 4 — CAD v2 — Cradle interchange (Mode 4)

- [ ] Refactor front shell to have a removable cradle plate held by 4 M3
screws. Cradle plate carries the camera mount holes. Shell carries the
cutout window matching the larger sensor's external footprint.
- [ ] Generate cradle_mega.stl — current Mega cradle as a removable plate.
- [ ] Generate cradle_bolt.stl — Bolt cradle as a matching plate. Same
4-corner mount pattern so plates are interchangeable.
- [ ] Verify cradle swap physically — print both, swap, verify each
camera seats correctly without modifications.

Phase 5 — Print queue update

- [ ] Create sku1-bolt-print-queue.md — 32 hour queue for Bolt-bar.
- [ ] Document slicer settings — Bolt-bar uses same ASA Standard 0.20mm
profile but smaller parts could go to 0.16mm for surface finish.
- [ ] Verify all STLs slice clean in OrcaSlicer — no errors, brim 5mm
generates, supports tree-auto only on shell_front_* (LED bezel) and
pod_top (fillet overhang).

Phase 6 — Software v2 (no changes for Mode 1+4)

- [ ] Verify Unity Player runs identically on Bolt-bar K11 — boot K11,
USB-C connect Bolt, run Unity Player linux-x86_64 build, fire publisher,
verify same visuals as Mac4 dev rig.
- [ ] Calibration JSON tuning — capture default calibration values for
Bolt-bar (probably need slightly higher diffNormMm because Bolt's
WFOV depth resolution differs from Mega's NFOV). Persist as factory
baseline.
- [ ] Update CODEX-CONTEXT.md and ARCHITECTURE.md to mention dual-SKU
support — same Unity, two physical bars.

Phase 7 — Packaging & manuals

- [ ] Bar packaging — design foam cutout for shipping carton.
Bar: 500×120×60mm. Pod: 200×120×100mm. Box: 600×280×220mm with foam.
- [ ] K11 packaging — keeps original GMKtec retail box, packed inside
the bar carton.
- [ ] Bolt packaging — keeps Orbbec retail box, packed inside.
- [ ] Cable bag — USB-C 2m + USB-C 1m + power brick + HDMI 2m optional.
- [ ] Quick-start card — single 4×6 card pointing to setup wiki URL,
QR code to wiki, contact email.
- [ ] Setup wiki at lume.app/setup or similar — covers wall-mounting,
cable connections, first-boot procedure, calibration walk-through,
F12 panel, troubleshooting.
- [ ] Photography for marketing — render hero shots from
hardware/cad/renders/tform/ are CAD-quality; for marketing we need
real-photo shots of a printed unit on a wall. Schedule a photoshoot
day after first SKU 1 is fully assembled.

Phase 8 — Pre-ship verification gates

- [ ] Boot test — fresh K11, fresh microSD/SSD with Ubuntu 24.04 +
Unity Player, plug in Bolt + UMA-8 + power, verify auto-start.
- [ ] Wall-mount test — install on real drywall with VESA bracket,
verify no sag over 24 hours, verify cable strain relief works.
- [ ] Thermal test — sustained 1-hour Performance-mode workload, log
K11 internal temps. Should stay <85°C with current vent design.
If above, increase vent count or upsize.
- [ ] Audio test — run with UMA-8 mic in same room, verify LUMF onset
detector fires correctly on real music. Spot-check transient counts.
- [ ] Demo loop — 60-minute Play session with synthetic depth + real
Femto + real audio, verify no memory leaks, no frame drops, no
Unity crashes.
- [ ] Calibration persistence — F12 tweak, exit, restart, verify values
persist. Verify across K11 reboots.

Phase 9 — Ship prep

- [ ] First customer order — accept first paid order. Manufacture timeline.
- [ ] Manufacturing cost analysis — capture true BOM cost including
filament, electricity, labor, packaging. Set retail price to 3× BOM
minimum.
- [ ] Returns policy — drafted in legal language.
- [ ] Support process — Mohamed's email or Discord handle for first
30 days of support per unit.

Open dependencies (block phase progression)

Highest-leverage immediate action (today, Apr 26)

The only thing that doesn't require physical hardware to start: writing
`lume-config-bolt.scad` with placeholder Bolt dimensions (140×39×30 plus
TBD mount pattern), and parameterizing `lume-shell.scad` to accept either
config. That's a half-day of CAD scaffolding that lands the Bolt-bar shell
ready to render the moment we measure the Bolt mount pattern on Apr 27.
Pin SCAD work to start now, finalize after Bolt arrives.