Enclosure Specification
Concept v1
Architecture shown: matte-black ASA FDM shell, separate screwed rear lid, broad adhesive dashboard pedestal, three-display front bezel, right-side encoder and USB-C access, antenna-clear region, and localized passive ventilation.
Status: rejected because it did not preserve the actual PCB appearance and component proportions.
Concept v2 — board-accurate
This revision uses the actual PCB Preview image as its visual datum and preserves the three oversized displays, upper-right encoder, mid-right USB-C receptacle, four mounting holes, and lower-right power cluster.
Product orientation
- Enclose the 125 × 65 mm FJ Cruiser Dashboard Compass PCB.
- The unit stands vertically on the vehicle dashboard.
- Use a widened, low-profile base/feet so the tall display assembly is stable and resists tipping.
- Passenger-facing side presents the three displays and rotary encoder; road-facing side contains the PCB rear and service access.
Architecture
- Printable two-part enclosure with a removable screwed rear lid.
- Prototype process: FDM.
- Material: black ASA suitable for automotive cabin temperature and UV exposure.
- Board retained using its mounting holes and internal standoffs.
- Separate base/shell and lid CAD assets in build123d so the lid can be hidden for inspection.
User-facing features
- Front bezel/window aligned to all three FJ15103AH displays.
- Right-side access for the PEC11R rotary encoder, including shaft/bushing and knob clearance.
- Right-side USB-C opening sized for a complete USB-C plug overmold and insertion reach, not only the receptacle.
- Reset and BOOT controls are service-access features with the rear lid removed unless geometry supports unobtrusive recessed access.
Electrical and RF constraints
- Preserve the ESP32-S3 antenna keepout and do not place metal fasteners, dense wall features, or conductive finishes immediately over the antenna region.
- Provide passive ventilation near the AP63203 buck stage and ESP32 without obstructing the antenna, display window, connector, or fasteners.
- Maintain clearance around the onboard LIS2MDL magnetometer; avoid magnetic steel hardware near the sensor. Prefer nonmagnetic stainless or brass fasteners where practical.
Mechanical requirements
- Follow actual PCB outline, mounting-hole coordinates, component bodies, display envelopes, encoder geometry, and USB-C geometry from the current layout.
- Provide at least 0.5 mm PCB-edge clearance and at least 2.0 mm above the tallest component for FDM.
- Nominal handled-case wall thickness: 2.4–3.2 mm.
- Use a consistent corner-radius family and a deliberate lid seam.
- No enclosure wall, boss, rib, vent, or fastener may intersect the PCB, components, antenna zone, USB plug corridor, encoder/knob sweep, or display viewing area.
Dashboard mounting
- Integrate a broad pedestal/foot suitable for automotive dashboard use.
- Default underside is a flat recessed pad area suitable for high-temperature automotive acrylic foam tape; no dashboard drilling is assumed.
Validation gates
- Generate and approve an enclosure concept image before CAD authoring.
- Verify board containment, standoff alignment, cutout alignment, USB insertion, encoder clearance, antenna clearance, lid access, connected-solid geometry, clear screw bores, and printable wall thickness before completion.