For a first try, the result looks encouraging. Besides the isses I've already mentioned, there are also some design flaws caused by the size of the endmill:
- the LED column should look like the one in the Y-Box, instead of being a U-shaped protrusion from the sidewall. The reason for this shape is that the bit doesn't fit between column and wall. I can solve this by moving the LED further away from the wall in a future layout revision. - the lanyard hole and column are missing. I included them in the CAD design but had to "if" them out because the bit is too wide for separating the column from the wall, let alone making the hole for the lanyard. The reason why I'm using such a large bit is that I need to go fairly deep (sheer walls of about 7 mm) and endmills typically have a diameter to depth ratio between 1:1.5 and 1:3. So I either have to find small bits with a larger ratio (and try not to break too may of them), add a tool change (use the large bit for the coarse work and a smaller one for the problem spots), or see if I can move things to more accessible locations. I could also use a drill, making a series of overlapping holes to remove most of the material, then move the drill sideways very gently (like a mill) to remove the bumps that remain. We'll see. Some research is clearly needed. Last but not least, a quick look at how the bottom side components align: http://downloads.qi-hardware.com/people/werner/anelok/tmp/case-top-flip.jpg The knob of the switch is precisely flush with the outside, the USB receptacle is reasonably close to the outside, and the memory card, while protruding "into" the inner wall, doesn't touch the outer wall. So all this worked as planned. - Werner _______________________________________________ Qi Hardware Discussion List Mail to list (members only): [email protected] Subscribe or Unsubscribe: http://lists.en.qi-hardware.com/mailman/listinfo/discussion
