feat(mechanical): IP54 weatherproofing kit (Issue #144) #152

sl-mechanical · 2026-03-02T09:58:45-05:00

sl-mechanical commented

2026-03-02 09:58:45 -05:00

Summary

ip54_enclosure.scad: sealed electronics box (220×160×90 mm internal) for Jetson/FC/ESC. 2 mm O-ring cord lid seal, 4× PG7 + 2× PG9 cable glands on rear wall, 40 mm fan + labyrinth filter duct (positive pressure), double-baffle labyrinth exhaust, 4× quarter-turn tool-free latches, heat sink pad recesses in lid (Jetson 60×40 mm, ESC 50×30 mm). Gasket DXF for silicone sheet alternative.
ip54_sensor_housings.scad: (A) IMX219 clear PC dome — O-ring sealed, anti-fog silica gel pocket, 4× M2 standoffs, retainer ring; (B) D435i RealSense housing — 3 mm IR-transparent PC window (>85% T at 850 nm), O-ring window frame, PG7 rear cap; (C) RPLIDAR static clear dome — Ø120 mm OD PC cylinder + disc cap, O-ring base ring, 3× quarter-turn retention clips.
ip54_BOM.md: full hardware list, thermal analysis (≤52 °C at 40 °C ambient, within 60 °C target), IP54 compliance checklist, mass ~930 g total kit.

Test plan

Open both .scad files in OpenSCAD — verify assembly previews render cleanly
Print enclosure lid, verify O-ring groove dimensions with caliper (2.2 mm W × 1.7 mm D)
Print fan duct, verify labyrinth inlet slots align to fan bore
Test quarter-turn latch engagement on post (90° rotation locks/unlocks)
Print IMX219 dome base ring, verify Ø55 mm PC dome seats on O-ring
Print RPLIDAR dome base, verify Ø58 mm BC bolt holes align to A1M8
Export ip54_gasket.dxf, d435i_window.dxf, confirm geometry
Splash test: steady water stream from all angles for 30 s on sealed box

Closes #144

🤖 Generated with Claude Code

## Summary - `ip54_enclosure.scad`: sealed electronics box (220×160×90 mm internal) for Jetson/FC/ESC. 2 mm O-ring cord lid seal, 4× PG7 + 2× PG9 cable glands on rear wall, 40 mm fan + labyrinth filter duct (positive pressure), double-baffle labyrinth exhaust, 4× quarter-turn tool-free latches, heat sink pad recesses in lid (Jetson 60×40 mm, ESC 50×30 mm). Gasket DXF for silicone sheet alternative. - `ip54_sensor_housings.scad`: (A) IMX219 clear PC dome — O-ring sealed, anti-fog silica gel pocket, 4× M2 standoffs, retainer ring; (B) D435i RealSense housing — 3 mm IR-transparent PC window (>85% T at 850 nm), O-ring window frame, PG7 rear cap; (C) RPLIDAR static clear dome — Ø120 mm OD PC cylinder + disc cap, O-ring base ring, 3× quarter-turn retention clips. - `ip54_BOM.md`: full hardware list, thermal analysis (≤52 °C at 40 °C ambient, within 60 °C target), IP54 compliance checklist, mass ~930 g total kit. ## Test plan - [ ] Open both `.scad` files in OpenSCAD — verify assembly previews render cleanly - [ ] Print enclosure lid, verify O-ring groove dimensions with caliper (2.2 mm W × 1.7 mm D) - [ ] Print fan duct, verify labyrinth inlet slots align to fan bore - [ ] Test quarter-turn latch engagement on post (90° rotation locks/unlocks) - [ ] Print IMX219 dome base ring, verify Ø55 mm PC dome seats on O-ring - [ ] Print RPLIDAR dome base, verify Ø58 mm BC bolt holes align to A1M8 - [ ] Export `ip54_gasket.dxf`, `d435i_window.dxf`, confirm geometry - [ ] Splash test: steady water stream from all angles for 30 s on sealed box Closes #144 🤖 Generated with [Claude Code](https://claude.com/claude-code)

sl-mechanical added 1 commit 2026-03-02 09:58:46 -05:00

feat(mechanical): IP54 weatherproofing kit (Issue #144 ) a70d9a2a71

Add sealed enclosures and sensor housings for outdoor IP54 protection:
- ip54_enclosure.scad: main electronics box (Jetson/FC/ESC), O-ring lid,
  fan+filter duct, PG7/PG9 cable glands, quarter-turn latches, heat sink
  recesses; gasket DXF export
- ip54_sensor_housings.scad: IMX219 clear PC dome (O-ring + anti-fog
  pocket), D435i IR-transparent window housing (PG7 rear cap), RPLIDAR
  static clear PC dome base ring (120 mm OD, O-ring, quarter-turn clips)
- ip54_BOM.md: hardware list, thermal analysis (≤52°C at 40°C ambient),
  IP54 compliance checklist, mass ~930g total kit

Co-Authored-By: Claude Sonnet 4.6 <noreply@anthropic.com>

sl-jetson merged commit 52250e28d6 into main

2026-03-02 10:07:28 -05:00

sl-jetson referenced this issue from a commit

2026-03-02 10:07:29 -05:00

Merge pull request 'feat(mechanical): IP54 weatherproofing kit (Issue #144)' (#152) from sl-mechanical/issue-144-weatherproofing into main

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Reference: seb/saltylab-firmware#152