feat(ark-flow): add Rev 2 case in STEP with board-slot clearance fix - #7
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dakejahl wants to merge 1 commit into
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feat(ark-flow): add Rev 2 case in STEP with board-slot clearance fix#7dakejahl wants to merge 1 commit into
dakejahl wants to merge 1 commit into
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Adds the ARK Flow case as STEP (plus matching STL), based on revised files supplied by a customer, with one interference defect corrected. The Rev 1 case slot is 1.5218 mm, exactly the modelled PCB thickness, so it has zero clearance for real board tolerance. Rev 2 opens it to 1.7000 mm. As supplied, the revised bottom case moved the connector cut-out back wall from y=4.8531 to y=4.6190, which clipped a bottom-side component by 0.092 mm^3. Restored to its Rev 1 position, giving 0.20 mm clearance. Verified with boolean interference against ARK_Flow_Rev_2_3D_Model.step and ARK_Flow_MR_Rev_1.0.step: 0.000000 mm^3 for both halves with the board seated, and the two halves mate at 0.000000 mm^3.
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@NickJ98 let's print this off and verify it. It would also be good to find the .step files for the other cases as .step is strictly better than .stl |
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Summary
Adds the ARK Flow case as STEP (with matching STL) at Rev 2, based on revised files a customer sent us, with one interference defect corrected before publishing. Rev 1 STLs are kept until a test print validates Rev 2.
Problem
The
case/directories in this repo only ship STL, which is a triangle mesh — customers can't mate to it, dimension it, or modify it without a mesh-to-solid conversion. That is what prompted the customer to send STEP files back to us.Comparing his files against Rev 1 showed they are not just a format conversion — the geometry changed. The significant change is the board slot: Rev 1 seats the board on a shelf 0.8000 mm below the parting face against a top-half ledge 0.7218 mm above it, giving a 1.5218 mm slot. That is exactly the modelled PCB thickness of
ARK_Flow_Rev_2_3D_Model.step, to four decimals — zero clearance, which fits the CAD model but not a real board with normal thickness tolerance. His revision opens it to 1.0000 + 0.7000 = 1.7000 mm.The revision also introduced a defect. The connector cut-out back wall in the bottom half moved inward from y=4.8531 to y=4.6190. Rev 1 cleared the bottom-side component at x[10.94, 18.94] by exactly 0.2000 mm; the revision spent that entire margin and went 0.034 mm past it, for 0.092 mm³ of interference. Every other change in the revision moves outward to add clearance, so this reads as an oversight rather than intent.
Solution
Restored that one wall to its Rev 1 position, leaving the rest of the revision intact. The cut removes 1.5735 mm³ and the part remains a single valid solid with an unchanged outer envelope.
Verified with boolean interference using
ark-hardware-jigs:ARK_Flow_Rev_2_3D_Model.step, board seatedARK_Flow_MR_Rev_1.0.stepBoth halves are written in the same coordinate frame as
ARK_Flow/model/, matching the existing Rev 1 STLs, so the case and PCBA open already assembled.Two things to confirm before this is merged:
manifest.tsv, the naming and the manifest rows should follow that.ARK_Flow_MR/case/currently holds byte-identical STLs toARK_Flow/case/. Rev 2 clears the MR board too, but it is not added there in this PR — leaving MR on Rev 1 is an inconsistency worth a decision.