enclosure-export

name	enclosure-export
model	claude-haiku-4-5-20251001
description	Export OpenSCAD enclosure parts to STL files for 3D printing
disable-model-invocation	true
allowed-tools	Bash, Read, Glob
argument-hint	["all|top|bottom|buttons|dpad|abxy"]

Enclosure STL Export for 3D Printing

Export individual enclosure parts to STL files for FDM/SLA 3D printing.

Argument (optional): all (default), or specific part name.

Prerequisites

Docker must be running with the OpenSCAD image built:

cd /Users/pierrejonnycau/Documents/WORKS/esp32-emu-turbo
docker compose build openscad

Export Commands

Export all printable parts

cd /Users/pierrejonnycau/Documents/WORKS/esp32-emu-turbo
mkdir -p hardware/enclosure/stl

# Top shell (display side)
docker compose run --rm openscad \
    -o /output/case_top.stl \
    -D 'part="case_top"' \
    /project/enclosure.scad

# Bottom shell (battery side)
docker compose run --rm openscad \
    -o /output/case_bottom.stl \
    -D 'part="case_bottom"' \
    /project/enclosure.scad

# D-pad cap
docker compose run --rm openscad \
    -o /output/dpad.stl \
    -D 'part="part_dpad"' \
    /project/enclosure.scad

# ABXY button caps (4 individual)
for btn in a b x y; do
    docker compose run --rm openscad \
        -o "/output/btn_${btn}.stl" \
        -D "part=\"part_btn_${btn}\"" \
        /project/enclosure.scad
done

# Start, Menu, Select caps
for cap in start menu select; do
    docker compose run --rm openscad \
        -o "/output/${cap}.stl" \
        -D "part=\"part_${cap}\"" \
        /project/enclosure.scad
done

# Shoulder buttons
docker compose run --rm openscad \
    -o /output/shoulder_l.stl \
    -D 'part="part_shoulder_l"' \
    /project/enclosure.scad

docker compose run --rm openscad \
    -o /output/shoulder_r.stl \
    -D 'part="part_shoulder_r"' \
    /project/enclosure.scad

Export a single part

docker compose run --rm openscad \
    -o /output/<part_name>.stl \
    -D 'part="<part_selector>"' \
    /project/enclosure.scad

Part Selector Reference

Part	Selector	Print Notes
Top shell	case_top	Print upside-down (flat face down)
Bottom shell	case_bottom	Print as-is (flat face down)
D-pad	part_dpad	Print cap-face down
Button A	part_btn_a	Print cap-face down
Button B	part_btn_b	Print cap-face down
Button X	part_btn_x	Print cap-face down
Button Y	part_btn_y	Print cap-face down
Start	part_start	Print cap-face down
Menu	part_menu	Print cap-face down
Select	part_select	Print cap-face down
Shoulder L	part_shoulder_l	Print cap-face down
Shoulder R	part_shoulder_r	Print cap-face down

3D Printing Recommendations

Material

• PLA/PETG for shells (strong, easy to print)
• TPU for button caps (flexible, better feel) — optional
• PLA for button caps works fine too

Print Settings (FDM)

• Layer height: 0.2mm (shells), 0.12mm (button caps for detail)
• Infill: 20-30% (shells), 100% (button caps)
• Supports: Not needed for shells (designed for supportless printing)
• Tolerances: 0.3mm clearance built into alignment lip design

Post-processing

• Light sanding on mating surfaces for smooth fit
• Test-fit button caps in cutouts before final assembly
• M3 heat-set inserts in screw boss holes (optional, can self-tap into PLA)

Post-export Verification

ls -la website/static/img/renders/*.stl 2>/dev/null || ls -la hardware/enclosure/stl/*.stl 2>/dev/null

Key Files

• hardware/enclosure/enclosure.scad — Main enclosure (all part selectors)
• hardware/enclosure/modules/*.scad — Component modules
• docker-compose.yml — OpenSCAD Docker service
• website/docs/enclosure.md — Design documentation