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Joshua King
2026-10-02 12:23:58 -04:00
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hardware/eye_mount/README.md
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# Eye mounts — first-fit CAD, not final print approval
This is a removable **board-carrier prototype** for the stationary Freddy mask.
It is built from the mask STEP and the official Waveshare
ESP32-S3-Touch-LCD-2.1 assembly. Coordinates are millimetres in the mask STEP.
`left` means the negative-X eye in that STEP; check the physical orientation
before printing. The unmounted circuit boards, plugged USB/UART cables, glued
mask seams, and print tolerances are **not** represented by the exported mask
assembly.
## What is here
- `mask_with_first_fit_mounts.step`: two mask head halves plus all mount parts,
for inspection in Shapr3D. Import as millimetres. The mask is reference
geometry, not part of the print job.
- `first_fit_mounts_in_mask_coordinates.step`: mount parts only, in their
candidate installed positions.
- `left_carrier` / `right_carrier`: rear ring with four 2.3 mm nominal M2
clearance holes matching the vendor board's asymmetric rear posts. Three
3.6 mm wide radial slots allow about 5 mm of in-plane placement adjustment.
- `*_pad_1..3`: small shell-conforming feet. The two upper feet use the brow;
the third uses the lower *outer* cheek rather than the steep temple or the
glued center seam. The 4.2 mm, 4 mm-deep blind bores are only **test pilots**
for a specific M3 heat-set insert. Confirm the insert's actual specification
and the printed wall thickness before installation.
- `*_sleeve_1..3`: stand-off sleeves between carrier and pads. Approximate
lengths are 2.0, 12.2–12.3, and 47.0 mm. The lower sleeve is 10 mm OD and
needs a straight M3 fastener/rod solution that is measured on the real mask.
- `*_trim_gauge`: 74.2 mm OD, 54.5 mm ID, 1.2 mm thick visual gauge to test
how a mask-colored annulus looks around a powered eye. It is **not** a
finished, retained cosmetic surround and must not touch the display glass.
The board centers in this candidate pose are X/Z = (-30, 196) and (56, 196),
with board origin Y=-15 and display pointing toward negative Y. That depth
cleared the vendor bare assembly in CAD; it is **not** a guarantee that the
actual plugged USB and UART cables, connector bends, indicator LED, or user's
Rev2.0 board will clear. The lower cheek pad makes this test layout sturdier
than a third pad on the sharply sloped side surface, but the 47 mm spacer and
mask-side adhesion need a physical load/fit test.
## Print and dry-fit sequence
1. Print **one eye** first: one carrier, pads 1–3, sleeves 1–3, and optionally
the trim gauge, using the matching `.stl` files. Do not print the mask STEP.
2. Compare the printed carrier's four holes with the actual board posts. Use
nonconductive hardware; choose screw lengths from the physical post depth,
not from CAD alone. Do not drive a screw into the PCB or display.
3. Hold the board/carrier behind the mask with the real USB and 4-pin UART
plugs fitted. Check both ports, wire bend radius, strain relief, and glass
clearance. The separate UART USB-C port remains unplugged for header RX.
4. Tape the three pads in place **temporarily**. Check whether their curved
faces match the glued print, whether the carrier slots align, and whether
the sleeves fit without loading or bending the board. Do not glue, drill,
heat-set, or force the mask during the first dry fit.
5. Power both eyes and inspect from normal visitor distance and close-up.
Check edge clipping, iris symmetry, dark-cavity visibility, and the red
onboard indicator. Use the trim gauge only to assess color/reveal; a true
integrated tapered surround still needs to be shaped and retained after
this fit check.
If the pads are eventually bonded to the rear shell, the board/carrier can be
removed by undoing its fasteners. The adhesive method and final fastener
stack are intentionally undecided until the physical dry fit. The carrier is
not intended to be bonded directly to the PCB or to the glued center seam.
Regenerate parts with:
```sh
uv run --no-project --with build123d python hardware/eye_mount/first_fit.py
```
For a repeatable check against a downloaded copy of the official Waveshare
board STEP, run `check_vendor_clearance.py /path/to/board.step` with the same
`uv run --no-project --with build123d python` prefix. The vendor file is not
committed here; its source is the [Waveshare wiki](https://www.waveshare.com/wiki/ESP32-S3-Touch-LCD-2.1).
hardware/eye_mount/check_vendor_clearance.py
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"""Check all official Waveshare STEP solids against the first-fit carrier/trim.
Usage: uv run --no-project --with build123d python \
hardware/eye_mount/check_vendor_clearance.py /path/to/ESP32-S3-Touch-LCD-2_1_asm.stp
"""
import sys
from pathlib import Path
from build123d import Pos, Rot, import_step
OUT = Path(__file__).resolve().parent
board = import_step(sys.argv[1]).solids()
print(f"Checking {len(board)} vendor solids")
def bbox_overlap(a, b):
return all(getattr(a.min, k) < getattr(b.max, k)
and getattr(b.min, k) < getattr(a.max, k)
for k in ("X", "Y", "Z"))
for side, x in (("left", -30.0), ("right", 56.0)):
mounts = [import_step(str(OUT / f"{side}_{name}.step"))
for name in ("carrier", "trim_gauge")]
clashes = []
for index, solid in enumerate(board):
placed = Pos(x, -15.0, 196.0) * Rot(90, 0, 0) * solid
for kind, mount in zip(("carrier", "trim"), mounts):
if not bbox_overlap(placed.bounding_box(), mount.bounding_box()):
continue
overlap = placed & mount
if overlap is not None and overlap.volume > 0.01:
clashes.append((index, kind, round(overlap.volume, 3)))
print(f"{side}: {len(clashes)} board/mount clashes {clashes[:30]}")
hardware/eye_mount/first_fit.py
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"""Export a *test-fit* eye-board carrier and cosmetic trim in mask STEP coordinates.
Run: uv run --no-project --with build123d python hardware/eye_mount/first_fit.py
The three mask pads per eye are modeled against the *CAD* shell, not the glued
print. Do not bond them to the mask until board/cable clearance and fit are
checked on the real assembly. Units are millimetres.
"""
import math
from pathlib import Path
from build123d import (
Align, Box, Compound, Cylinder, Pos, Rot, Vector, export_step, export_stl,
import_step,
)
ROOT = Path(__file__).resolve().parents[2]
OUT = Path(__file__).resolve().parent
MASK = import_step(str(ROOT / "stls/freddy_fazbear_mask.step"))
HEAD_HALVES = MASK.solids()[:2]
# The official Waveshare CAD has 2 mm nominal bores in the four rear posts.
# Their centers are not a square. These are in the vendor board's local XY.
BOARD_POSTS = [(-29.5, 13.63818, -6.0), (29.5, 13.63818, -6.0),
(-18.0, -27.06012, -6.1), (18.0, -27.06012, -6.1)]
BOARD_ORIGIN_Y = -15.0
EYE_CENTERS = [(-30.0, 196.0), (56.0, 196.0)]
def cyl(radius, height, x=0, y=0, z=0):
return Pos(x, y, z) * Cylinder(
radius, height, align=(Align.CENTER, Align.CENTER, Align.MIN)
)
def arm(a, b, width, z0, height):
"""A straight XY rib joining a point on the carrier ring to an anchor."""
d = Vector(b[0] - a[0], b[1] - a[1])
angle = math.degrees(math.atan2(d.Y, d.X))
return (Pos((a[0] + b[0]) / 2, (a[1] + b[1]) / 2, z0 + height / 2)
* Rot(0, 0, angle) * Box(d.length, width, height))
def radial_slot(x, y, radius=1.8, travel=5.0):
"""Through-slot, with 5 mm adjustment along its radial direction."""
r = (x * x + y * y) ** 0.5
ux, uy = x / r, y / r
a = (x - ux * travel / 2, y - uy * travel / 2)
b = (x + ux * travel / 2, y + uy * travel / 2)
return (cyl(radius, 5, *a, -13)
+ cyl(radius, 5, *b, -13)
+ arm(a, b, 2 * radius, -13, 5))
def carrier(outer_sign):
# Rear carrier is an open ring, well behind the PCB parts. Its four small
# stand-offs reach the vendor board posts at local Z=-6.0. Screw from back.
part = cyl(37.0, 3.0, z=-12.0) - cyl(29.0, 5.0, z=-13.0)
for x, y, back_z in BOARD_POSTS:
part += cyl(3.5, back_z + 12.0, x, y, -12.0)
# Two brow attachments and one lower/outer cheek attachment. The lateral
# temple surface changes depth by >20 mm under a 12 mm pad; the lower
# cheek is smoother, though it needs a much longer stand-off sleeve.
anchors = [(-20.0, 42.0), (20.0, 42.0), (outer_sign * 20.0, -38.0)]
for x, y in anchors:
r = (x * x + y * y) ** 0.5
start = (x * 34.0 / r, y * 34.0 / r)
part += arm(start, (x, y), 8.0, -12.0, 3.0)
part += cyl(6.0, 3.0, x, y, -12.0)
for x, y, _ in BOARD_POSTS:
part -= cyl(1.15, 8.0, x, y, -13.0) # 2.3 mm M2 clearance
for x, y in anchors:
part -= radial_slot(x, y) # 3.6 mm M3 clearance
return part, anchors
def trim():
# A simple first-fit matte/paintable annulus sits 0.5 mm in front of the
# Waveshare face; ID 54.5 mm does not press on the ~53 mm lit circle.
# It is a placement/appearance gauge, not a finished snap-fit surround.
return cyl(37.1, 1.2, z=3.9) - cyl(27.25, 2.2, z=3.4)
def place_at_eye(shape, center):
return Pos(center[0], BOARD_ORIGIN_Y, center[1]) * Rot(90, 0, 0) * shape
def mask_pad(shell, x, z):
# The rear surface is found along Y at this X/Z; the farthest intersection
# is the surface a pad placed from behind will meet.
from build123d import Axis
def rear_at(px, pz):
hits = shell.find_intersection_points(Axis((px, -200, pz), (0, 1, 0)))
return max((point.Y for point, _ in hits), default=None)
rear_y = rear_at(x, z)
samples = [rear_y]
for radius in (3.0, 6.0):
for step in range(24):
theta = step * math.tau / 24
hit = rear_at(x + radius * math.cos(theta),
z + radius * math.sin(theta))
if hit is not None:
samples.append(hit)
# Size the *rear* plane from the farthest-back point under the whole pad so
# its sleeve stays off the mask.
back_y = max(samples) + 2.0
front_y = min(samples) - 1.0
# A small sacrificial pad is cut to the nominal shell surface. Actual
# print/glue variation needs filler or a foam/epoxy bond after dry fit.
blank = (Pos(x, back_y, z) * Rot(90, 0, 0)
* cyl(6.0, back_y - front_y))
pad = blank - shell
# 4.2 mm pilot for a test M3 heat-set insert, inserted from behind.
bore = (Pos(x, back_y + 0.1, z) * Rot(90, 0, 0)
* cyl(2.1, 4.1))
pad -= bore
return pad, rear_y, back_y
pieces = []
for index, (shell, center) in enumerate(zip(HEAD_HALVES, EYE_CENTERS)):
side = "left" if index == 0 else "right" # mask STEP negative/positive X
sign = -1 if index == 0 else 1
local_carrier, anchors = carrier(sign)
world_carrier = place_at_eye(local_carrier, center)
world_trim = place_at_eye(trim(), center)
export_step(world_carrier, str(OUT / f"{side}_carrier.step"))
export_stl(local_carrier, str(OUT / f"{side}_carrier.stl"))
export_step(world_trim, str(OUT / f"{side}_trim_gauge.step"))
export_stl(trim(), str(OUT / f"{side}_trim_gauge.stl"))
pieces.extend([world_carrier, world_trim])
print(f"{side}: carrier {world_carrier.volume:.1f} mm^3, "
f"trim {world_trim.volume:.1f} mm^3")
for number, (lx, ly) in enumerate(anchors, 1):
pad, rear_y, back_y = mask_pad(shell, center[0] + lx,
center[1] + ly)
export_step(pad, str(OUT / f"{side}_pad_{number}.step"))
export_stl(pad, str(OUT / f"{side}_pad_{number}.stl"))
pieces.append(pad)
gap = -6.0 - back_y # carrier front to pad rear face
sleeve_outer_radius = 5.0 if gap > 30.0 else 3.5
sleeve = (Pos(center[0] + lx, -6.0, center[1] + ly)
* Rot(90, 0, 0)
* (cyl(sleeve_outer_radius, gap) - cyl(1.8, gap)))
export_step(sleeve, str(OUT / f"{side}_sleeve_{number}.step"))
export_stl(cyl(sleeve_outer_radius, gap) - cyl(1.8, gap),
str(OUT / f"{side}_sleeve_{number}.stl"))
pieces.append(sleeve)
print(f" pad {number}: X={center[0]+lx:.1f}, Z={center[1]+ly:.1f}, "
f"rear shell Y={rear_y:.1f}, sleeve={gap:.1f} mm, "
f"pad volume={pad.volume:.1f} mm^3")
export_step(Compound(children=pieces), str(OUT / "first_fit_mounts_in_mask_coordinates.step"))
export_step(Compound(children=[*HEAD_HALVES, *pieces]),
str(OUT / "mask_with_first_fit_mounts.step"))
print("Exported test-fit STEP and STL parts to", OUT)
hardware/eye_mount/first_fit_mounts_in_mask_coordinates.step
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hardware/eye_mount/left_carrier.step
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hardware/eye_mount/left_carrier.stl
BIN
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hardware/eye_mount/left_pad_1.step
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ISO-10303-21;
HEADER;
FILE_DESCRIPTION(('Open CASCADE Model'),'2;1');
FILE_NAME('Open CASCADE Shape Model','2026-09-27T15:22:16',('Author'),(
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FILE_SCHEMA(('AUTOMOTIVE_DESIGN { 1 0 10303 214 1 1 1 1 }'));
ENDSEC;
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hardware/eye_mount/left_pad_3.step
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hardware/eye_mount/left_pad_3.stl
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hardware/eye_mount/left_sleeve_1.step
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hardware/eye_mount/left_sleeve_2.step
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hardware/eye_mount/left_sleeve_3.step
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hardware/eye_mount/left_trim_gauge.step
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hardware/eye_mount/left_trim_gauge.stl
BIN
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hardware/eye_mount/mask_with_first_fit_mounts.step
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View File
File diff suppressed because it is too large Load Diff
hardware/eye_mount/right_carrier.step
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File diff suppressed because it is too large Load Diff
hardware/eye_mount/right_carrier.stl
BIN
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hardware/eye_mount/right_pad_1.step
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View File
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hardware/eye_mount/right_pad_3.stl
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hardware/eye_mount/right_sleeve_1.step
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hardware/eye_mount/right_sleeve_1.stl
BIN
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Binary file not shown.
hardware/eye_mount/right_sleeve_2.step
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ISO-10303-21;
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hardware/eye_mount/right_sleeve_2.stl
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hardware/eye_mount/right_sleeve_3.step
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ISO-10303-21;
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hardware/eye_mount/right_sleeve_3.stl
BIN
View File
Binary file not shown.
hardware/eye_mount/right_trim_gauge.step
+273
View File
@@ -0,0 +1,273 @@
ISO-10303-21;
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ENDSEC;
END-ISO-10303-21;
hardware/eye_mount/right_trim_gauge.stl
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