LUME Wood Enclosure Fabrication Spec

LUME Wood Enclosure Fabrication Spec

Date: 2026-05-11
Status: wood prototype spec, updated for stacked Femto Mega + Femto Bolt + NF-A8 pod fan.

This replaces the large 3D-printed outer shell and pod for the next physical prototype. Keep the CAD as the source of truth for the original Mega/Arducam placement, but build the body as a serviceable wood T-form enclosure with an internal two-shelf depth-sensor stack and a real 80 mm top-exhaust fan.

Use the dedicated Wood V2 printable support kit for the current prototype:

• Source: `../lume-wood-v2-printables.scad`
• STL exports: `../exports/wood-v2/`
• OrcaSlicer projects: `../print/3mf-current/wood-v2/`
• Print queue: `../print/WOOD_V2_PRINT_QUEUE.md`

The wood route does not need the printed shell halves or printed pod halves unless we decide to return to the ASA enclosure later.

Older printed internals remain useful as templates where helpful:

• `femto_mount.stl`
• `arducam_mount.stl` x 2
• `cable_backbone.stl`
• `pod_compute_sled.stl`

Current Hardware Target

Do not use the old Jetson/SVPRO/Bolt-only plan for this prototype.

Current build:

Dimension note: the old local `lume-config-bolt.scad` file still has a placeholder Bolt envelope of `140 x 39 x 30 mm`. For this wood stack, use the current official Orbbec Femto Bolt hardware envelope of `115.30 x 64.95 x 40.26 mm` until the physical unit is calipered.

Coordinate Convention

All dimensions below are millimeters. Do not read these as centimeters. For example, the front bar is `520 mm` wide, which is `52.0 cm`, about `20.47 in`.

• X = left/right across the bar.
• Y = front/back depth.
• Z = vertical height.
• Front panel coordinates in this document are measured from the lower-left corner of the outside face. Up is +Z, right is +X.
• Wood front-face centers:
• Femto Mega window center: X = 0, Z = 65.
• Femto Bolt window center: X = 0, Z = 125.
• Left Arducam: X = -180, Z = 85.
• Right Arducam: X = +180, Z = 85.

Recommended Wood Envelope

The CAD printed shell is `500 W x 120 H x 85 D`. For the stacked Mega + Bolt wood version, increase height and depth so the sensors can sit on shelves without crowding their cables or vents.

Quick inch equivalents:

• Front sensor bar: about `20.47 x 6.69 x 4.33 in`.
• Rear compute pod: about `9.45 x 6.69 x 7.87 in`.
• Top display tray: about `12.40 x 3.54 in`.
• Femto window: about `4.80 x 1.97 in`.
• Rear service window: about `6.30 x 2.95 in`.

Material recommendation:

• 6 mm Baltic birch plywood for most panels in the first prototype.
• 9 mm Baltic birch for the B1 front face, because the stacked sensor cutouts leave a narrow center strip.
• 9 mm Baltic birch or a metal backing plate for any VESA/wall-mount load.
• Paint the inside matte black before final assembly.
• Use black acrylic, smoked acrylic, or a painted thin bezel plate on the front if the wood cutouts look rough.

Front Bar Face

Front panel blank: `520 W x 170 H`.

Use lower-left origin coordinates.

Arducam mount-hole examples:

• Left Arducam hole centers: `(66, 71)`, `(66, 99)`, `(94, 71)`, `(94, 99)`.
• Right Arducam hole centers: `(426, 71)`, `(426, 99)`, `(454, 71)`, `(454, 99)`.

The side Arducams do not overlap either Femto window. The nearest lens edge remains more than 100 mm from the center depth-sensor openings.
The large front status-light aperture was removed from this cut. If a status light is needed later, put a small panel indicator on a side or service plate instead of weakening B1.

Top Panel And Display Tray

Top panel blank: `520 W x 110 D`.

Use top-view lower-left origin coordinates, where X runs left/right and Y runs front/back.

The monitor should sit on top of the bar. Do not flush-mount it through the wood until the exact case thickness and cable exit side are measured.
The tray should be visually centered on B3. The cable slot may stay off-center to match the display connector side.

Rear Bar To Pod Interface

Back panel of the bar needs one large central umbilical opening into the pod.

This opening carries:

• Femto Mega rear sleeve area.
• Femto Bolt USB-C path.
• Femto data/power cable path.
• Left and right Arducam USB-C leads.
• Display mini HDMI.
• Display USB-C power/data.
• Mic USB and low-bandwidth/status wiring if installed.

Internal Sensor Shelf Stack

Build a simple removable shelf tower in the center of the bar. Do not permanently glue the shelves until both sensors are test-fitted with cables attached.

Practical build:

• Use two vertical side rails or aluminum L-brackets on either side of the stack.
• Screw shelves into the rails so each shelf can be removed.
• Keep the rail height fixed to the front cutouts. Use forward/back slots or thin shims for depth correction, not vertical slots.
• Put thin neoprene/foam under each camera to remove vibration.
• Add a front retaining lip or strap, but never cross the lens/sensor windows.
• Leave at least 8-10 mm vertical air gap between the Mega top and Bolt shelf.
• Keep the Mega rear cooling channel open. Do not pack foam behind it.

Important sensor note: the Mega and Bolt are both depth cameras. Do not assume both active depth emitters can run simultaneously without interference testing. The safe prototype mode is one active depth camera at a time, or a later synchronized/staggered mode after software validation.

Rear Compute Pod

Pod outside size: `240 W x 170 H x 200 D`.

Recommended construction:

• Removable top or removable rear panel.
• K11 on standoffs or a tray, bottom fan facing a vented floor.
• Ports facing the rear service window.
• Side USB extension on the right side for the Bluetooth transporter / Sony adapter path.

Pod rear panel:

Pod right side:

Pod ventilation:

Use a metal or printed 80 mm grille on the outside of P3. Mount the fan body under P3 so the top remains protected and the fan pulls warm pod air out. Keep at least 12 mm air gap below the K11. Do not block the Femto Mega cooling channel, Mega rear sleeve, or Bolt USB-C exit.

Electrical note: the NF-A8 FLX is a `12 V`, 3-pin fan. Do not power it from a plain 5 V USB port. The design leaves room for the fan lead to route down the right side of the pod, but the final build still needs a small 12 V fan power/controller path unless the compute/power setup exposes a suitable 12 V fan header.

Assembly Order

1. Cut the wood panels oversize by 1-2 mm, then sand to final fit.
2. Dry-fit the empty bar and pod before drilling sensor holes.
3. Drill or route the front sensor openings using the coordinate table above.
4. Install the two center shelf rails.
5. Mount the Femto Mega on the lower shelf, confirming the full front black pill window is visible.
6. Mount the Femto Bolt on the upper shelf, confirming the full front sensor window is visible.
7. Mount the left and right Arducams and confirm no lens edge is covered by wood.
8. Install cable clips along the bottom inside of the bar and along the rear shelf rails.
9. Route all sensor/display cables to the central bar-to-pod feedthrough.
10. Mount the K11 in the pod with ports facing the rear service window.
11. Mount the NF-A8 FLX to the underside of P3 with airflow exhausting upward through the grille.
12. Add the right-side USB extension before closing the pod.
13. Plug everything in while the pod top or rear remains open.
14. Bench-test Mega, Bolt, Arducams, mic, Bluetooth/Sony adapter, display, and the 12 V fan.
15. Only after the bench test, paint/final-finish and close the box.

Cable Plan

Use direct K11 ports for high-bandwidth sensors whenever possible.

Buy or confirm:

• short right-angle mini HDMI cable for the display.
• short right-angle USB-C cable for the display.
• short right-angle USB-C cable for the Femto Bolt.
• two short USB-C cables for the Arducams.
• one panel-mount USB-A or USB-C extension for the right-side service slot.
• rubber grommet or edge trim for the 170 x 125 feedthrough.
• 80 mm fan grille for the NF-A8 top exhaust.
• confirmed 12 V fan power/controller path for the NF-A8 FLX.
• cable clamps, zip-tie anchors, and adhesive-backed tie mounts.

Required Physical Measurements Before Final Cutting

These are still real-world checks, even with the wood approach:

Friend-Facing Cut Summary

Build one T-shaped enclosure:

• Main bar: `520 x 170 x 110 mm`.
• Rear pod: `240 x 170 x 200 mm`, centered behind the bar.
• Top monitor tray: `315 x 90 mm`, centered on the bar top.
• Front has two stacked center Femto windows and two symmetric Arducam holes. No large front status-light hole in this version.
• Back/pod has one large central cable feedthrough, one rear service window, one right-side USB service slot, bottom intake ventilation, and a real NF-A8 FLX fan mounted as the top exhaust.

The exact front panel drill map is in `lume-wood-enclosure-mockup.html`. A spreadsheet-friendly cut list is in `lume-wood-cut-list.csv`.

Source Notes

• Femto Mega dimensions are from `FEMTO_MEGA_FIT_AUDIT.md` and the user-supplied Orbbec datasheet.
• Femto Bolt dimensions are from Orbbec's current hardware specifications page: `https://www.orbbec.com/documentation/femto-bolt-hardware-specifications/`.
• Noctua NF-A8 FLX fan dimensions are from Noctua's current NF-A8 FLX specifications page: `https://www.noctua.at/en/products/nf-a8-flx/specifications`.
• K11, display, and Arducam values follow `LUME_CURRENT_BUILD_SPEC.md` until physical caliper verification.