Session State

Session State

Current task: LUME CAD validation for the real hardware BOM.

Progress:
- K11 is the active compute path; Jetson-era internals are legacy.
- ZHAOCAILIN 11.3 inch display is modeled as a top cradle with a cable pass-through, not a structural top cutout.
- Arducam IMX586 USB camera is modeled in the right-front bay with a new printable mount.
- Approval renders are in `hardware/cad/renders/approval/`.
- Validation STLs are in `hardware/cad/exports/approval-v2/`.
- Symmetric two-Arducam variant is available with `ARDUCAM_LAYOUT="dual"`, mockups in `hardware/cad/renders/approval/approval_symmetric_*`, and STLs in `hardware/cad/exports/approval-symmetric/`.
- Femto Mega datasheet fit audit completed in `hardware/cad/FEMTO_MEGA_FIT_AUDIT.md`; rear feedthrough is now 87 x 38mm and Femto mount is a bottom/side cradle.
- Current print manifest is `hardware/cad/PRINT_APPROVAL_QUEUE_CURRENT.md`; older queue docs are marked stale and existing prearranged 3MFs should be rebuilt before final printing.
- Legacy/stale labels were added to old Jetson/SVPro-era plans and slicing docs so the active truth files are `LUME_CURRENT_BUILD_SPEC.md`, `LUME_SYMMETRIC_CAMERA_VARIANT.md`, `FEMTO_MEGA_FIT_AUDIT.md`, and `PRINT_APPROVAL_QUEUE_CURRENT.md`.
- Wiring/service access updated: pod has a 150 x 64mm rear K11 service window, matching VESA plate window, and a 44 x 18mm right-side service slot for USB/Bluetooth/Sony adapter extension access. Plan doc: `hardware/cad/LUME_WIRING_SERVICE_PLAN.md`.
- K11 CAD dimensions updated to official GMKtec 132 x 125 x 58mm. OrcaSlicer 3MF approval plates generated at `hardware/cad/print/3mf-current/approval-v2/` and `hardware/cad/print/3mf-current/approval-symmetric/`. Blender approval renders generated at `hardware/cad/renders/blender-approval-single/` and `hardware/cad/renders/blender-approval-symmetric/`.
- Long unattended render completed 2026-04-30 around 13:25: 4K/128-sample Blender approvals are in `hardware/cad/renders/blender-approval-single-4k/` and `hardware/cad/renders/blender-approval-symmetric-4k/`. Combined visual sheet: `hardware/cad/renders/blender-approval-4k-contact-sheet.png`. The temporary `caffeinate` guard was stopped after completion.
- Symmetric dual-Arducam internals plate was rebuilt after Orca found the old `02_internals_dual_arducam.3mf` had a broken layout with objects off the bed. The old file is now in `hardware/cad/print/3mf-current/approval-symmetric/legacy-broken-layout/02_internals_dual_arducam_DO_NOT_PRINT_broken-layout.3mf`; use `hardware/cad/print/3mf-current/approval-symmetric/02_internals_dual_arducam_ASA_READY.3mf`.
- User selected the symmetric dual-Arducam variant as the active approval path.
- `02_internals_dual_arducam_ASA_READY.3mf` has ASA settings, 0.20mm layers, 4 walls, 5 top/bottom layers, 25
- Symmetric fit coupons were opened in Orca as `hardware/cad/print/3mf-current/approval-symmetric/01_coupons.3mf` and sliced clean in GUI. Final coupon review assets: `hardware/cad/print/gcode-review/symmetric-coupons-asa-ready/orca-gui-preview-final.png` and `hardware/cad/print/gcode-review/symmetric-coupons-asa-ready/plate_1.gcode`. Estimate is about 4h44m and about 44g ASA. Coupon supports are off. Orca CLI segfaults on the legacy coupon 3MF, so the review G-code was generated directly from the four clean coupon STLs with the same ASA settings.
- Completed full symmetric shell orientation matrix using explicit Neptune 4 Max + ASA settings. Report: `hardware/cad/print/gcode-review/symmetric-shell-all-orientation-tests/README.md`. Default shell orientations are rejected. Best supported candidates are 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 supported shell estimate is about 60h27m and 651g ASA. Shells are slicer-feasible but not final-print approved until physical gates and Orca visual preview pass.
- Plate 7 default pod batch is blocked. Default pod batch slice in `hardware/cad/print/gcode-review/symmetric-pod-asa-ready/` is marked DO NOT PRINT after Orca estimated ~3d23h46m / 976g ASA. Added CAD-side print-orientation wrapper `hardware/cad/lume-pod-print-orientation.scad`, print-oriented STLs in `hardware/cad/exports/approval-symmetric-print-oriented/`, and pod light profile `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 probably should be split into smaller jobs.
- Split pod jobs are now 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. Clean review queue symlink folder is `hardware/cad/print/gcode-review/CURRENT_SYMMETRIC_REVIEW_QUEUE_2026-04-30/`.
- Unity project status checked after reboot/crash: project exists at `software/demo/unity/lume_pcloud`, requires Unity Editor `6000.3.2f1`, URP `17.0.4`, Shader Graph `17.0.4`, VFX Graph `17.0.4`. Important correction: the local `/Applications` check only describes this Mac/session. Per `software/demo/TOPOLOGY-CORRECTION-2026-04-26.md`, Mac4 is the actual Unity Editor / GUI smoke-test host and already has Unity Hub + Unity 6000.x editors installed. Mac5 remains the synthetic fallback/runtime host.
- Duncan/Fewkes feature status: repo uses "Duncan Fewkes" references, not "Finch". Reference corpus exists at `software/demo/unity/lume_pcloud/Reference/Duncan/` with indexed analyses/reels; `software/demo/DUNCAN-GAP-ANALYSIS.md` is partially stale because newer files now include fluid sim, mocopi receiver/animator, display controller, skeleton-fluid injector, calibration panel, VFX editor, and transient force pusher.
- Patched Unity hygiene after audit: added deterministic `.meta` files for all missing new Unity scripts/compute assets, added `com.unity.ugui` to `Packages/manifest.json`, and added `using Lume;` to `Assets/Scripts/Vfx/LumeVfxEditor.cs` so it can see `LumeFluidSimPreset`. Static checks now show no missing `.meta` for `.cs/.compute/.shader/.mat/.asset/.unity` files and manifest JSON parses.
- Marked `software/demo/DUNCAN-GAP-ANALYSIS.md` with a stale-status warning so it is used as a checklist, not the active shipped-state source.
- Added `hardware/cad/PRINT_TIMELINE_2026-05-02.md` with the current Orca queue status and a Saturday May 2 start schedule. With operator-friendly starts and no reprints, full queue completion is Friday May 8 around 1:23 PM; active queue totals about 5d10h print time and 1.33kg ASA plus calibration/waste.
- Cloud approval prototype created/updated in Claude Design at `https://claude.ai/design/p/019debf9-ec40-70ca-8d8b-eb94509e887d`. Active file is `LUME Approval Board.html`; print/PDF file is `LUME Approval Board-print.html`. It shows the symmetric dual-Arducam build with centered Femto Mega, left/right Arducam IMX586 cameras, top ZHAOCAILIN display cradle, rear K11 pod, wiring view, exploded view, print timeline, and physical gates. Status was corrected to real-world not-started state: `0 of 5 physical gates passed`, `Stages Done 0/11`, `Queue Totals Done 0 of 11`, and action `Approve Next Gate`.

Open checks:
- Physically approve the coupon layout, then print coupons before any shell plates.
- Use the Claude Design approval board for visual signoff, but do not treat it as print authorization; physical next step is still Elegoo power-on, ASA calibration cube, then fit coupons.
- Use `hardware/cad/print/gcode-review/CURRENT_SYMMETRIC_REVIEW_QUEUE_2026-04-30/` as the clean review queue.
- Visually review the best shell candidate G-code in Orca Preview before any large shell print.
- Visually preview the print-oriented light pod path, then split the pod into smaller jobs or reduce pod shell mass before any pod shell print.
- Caliper ZHAOCAILIN monitor width/depth/thickness and exact mini HDMI/USB-C exit.
- Confirm Arducam metal-case screw pitch and exposed mounting holes.
- Caliper Femto Mega bottom 1/4-20 thread location before finalizing that screw hole.
- Approve the ZHAOCAILIN display orientation; public listing gives 305 x 80 x 60mm but CAD currently renders a slim top-cradle placement from the 305 x 80mm face footprint.
- Finalize display retention/strain relief, USB/power architecture, service access, hardware BOM, and powered thermal validation.
- Rebuild OrcaSlicer 3MF plates only after approval, using either `exports/approval-v2/` or `exports/approval-symmetric/`.
- Use Mac4 for Unity Editor work. Open/sync `software/demo/unity/lume_pcloud` on Mac4, run the Unity GUI smoke test there, then update the Duncan gap file to reflect what is actually shipped now.