Add inset screen enclosure variant

.specs/019-inset-enclosure.md

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+# 019: Inset Screen Enclosure Variant
+
+**Branch**: `feature/inset-enclosure`
+**Created**: 2026-03-09
+**Status**: Implemented
+
+## Summary
+
+Alternative enclosure design where the WT32-SC01 Plus drops INTO the box from the top, with walls surrounding the screen for protection. Unlike the flush-mount design in `bbq-case.scad`, this variant has the PCB sitting inside the cavity with the screen recessed 1mm below the wall top. Screws from below through the floor hold the PCB to internal standoffs. Includes a test ring part for quick fitment checks without printing the full box.
+
+Standoff height was corrected +5/16" based on test ring print — the original posts were too low. Test ring slimmed from 25mm to 15mm for faster print iteration.
+
+## Requirements
+
+- PCB drops into box from the top; walls surround the screen on all sides
+- Screen recessed 1mm below wall top for protection
+- M3 screws from below through floor and standoffs into PCB mounting holes
+- Counterbored screw heads flush with bottom of box
+- Tighter PCB tolerance (0.3mm per side vs 0.5mm in flush version)
+- Same panel-mount holes as flush version: 3x probe jacks, DC barrel jack, RJ45 cutout
+- Same carrier board standoffs and ventilation slots
+- Kickstand with hinge slot compatible with flush version
+- Test ring part for quick PCB fitment printing (~15mm tall, captures standoff tops + PCB pocket + screen lip)
+- Standoff height adjusted +5/16" per physical test ring print
+
+## Design
+
+### Key Differences from Flush Version (bbq-case.scad)
+
+| Parameter | Flush (`bbq-case.scad`) | Inset (`bbq-case-inset.scad`) |
+|-----------|------------------------|-------------------------------|
+| PCB mounting | Bezel lip frames screen from front | PCB drops into box from top |
+| Tolerance | 0.5mm per side | 0.3mm per side |
+| Wall relationship | Front bezel + rear shell (2 parts) | Single box, open top |
+| Screen protection | Bezel lip only | Full wall surround, 1mm recess |
+| Parts | 3 (front bezel, rear shell, kickstand) | 3 (box, kickstand, test ring) |
+
+### Parametric Variables (differences from flush version)
+
+```scad
+tolerance = 0.3;          // Tighter than flush version (0.5mm)
+screen_recess = 1;        // Wall height above screen glass (mm)
+rj45_w = 16;              // RJ45 panel-mount cutout (replaces USB-C cutout)
+rj45_h = 14;
+
+// Standoff height corrected per test ring fit check
+standoff_h = inner_d - wt32_post_h + 0.5 + 25.4*5/16;  // +5/16"
+```
+
+### Test Ring
+
+Slices the top 15mm of the box — just enough to capture the standoff tops, full PCB pocket, and screen lip. Print this first to verify PCB fitment before committing to the full box print.
+
+## Files to Modify
+
+| File | Change |
+|------|--------|
+| `enclosure/bbq-case-inset.scad` | New file — inset screen enclosure variant |
+| `enclosure/stl/bbq-case-inset-box.stl` | Exported STL for the inset box |
+| `enclosure/stl/bbq-case-inset-kickstand.stl` | Exported STL for the kickstand |
+| `enclosure/stl/bbq-case-inset-test-ring.stl` | Exported STL for the test ring |
+
+## Test Plan
+
+- [x] bbq-case-inset.scad renders all three parts without errors in OpenSCAD
+- [x] Standoff height includes +5/16" correction from test ring print
+- [x] Test ring height reduced to 15mm for faster print iteration
+- [x] STLs exported for box, kickstand, and test ring

enclosure/bbq-case-inset.scad

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+// ============================================================
+// Pit Claw Temperature Controller Enclosure — INSET SCREEN
+// WT32-SC01 Plus drops INTO the box; walls surround the screen
+// for protection. Screws still from below through floor.
+// Open in OpenSCAD, set 'part' variable, render, export STL
+// ============================================================
+
+// === PART SELECTOR ===
+// Set to "all", "box", "kickstand", or "test_ring" to render
+part = "all";
+
+// === Board Dimensions ===
+// WT32-SC01 Plus — measure your board with calipers and adjust
+wt32_pcb_w = 60;        // PCB width — short edge (mm)
+wt32_pcb_h = 92;        // PCB height — long edge (mm)
+wt32_pcb_d = 12.1;      // PCB total thickness including screen (mm) — measured 61/128"
+carrier_w = 50;          // Carrier perfboard width (mm)
+carrier_h = 70;          // Carrier perfboard height (mm)
+carrier_d = 15;          // Tallest component on carrier board (mm)
+
+// === WT32 Mounting Holes ===
+// 4 holes: 2 near top, 2 near bottom (measured from actual board)
+// Hole-to-hole spans: 52mm wide × 75mm tall
+wt32_hole_inset_w = 4;   // All holes: inset from width edges (mm) → 52mm span
+wt32_top_inset_h = 10.2; // Top 2 holes: inset from top edge (mm)  ┐ 75mm span
+wt32_bot_inset_h = 6.8;  // Bottom 2 holes: inset from bottom edge (mm) ┘ shifted ~1.2mm toward bottom
+wt32_post_h = 6.5;       // Height of PCB posts below board (~1/4", with clearance)
+wt32_post_od = 6;        // Outer diameter of PCB mounting posts (mm)
+
+// === Enclosure ===
+wall = 2.5;               // Wall thickness (mm)
+corner_r = 4;             // Corner radius (mm)
+tolerance = 0.3;          // Extra clearance per side for PCB fitment (mm)
+screw_d = 3.0;            // M3 screw shaft diameter (mm)
+screw_head_d = 6;         // M3 screw head diameter (mm)
+screw_head_recess = 1.5;  // Depth to recess screw heads in floor (mm)
+screen_recess = 1;        // Wall height above screen glass (mm)
+
+// === Panel Mount Holes ===
+probe_jack_d = 6.2;       // 2.5mm mono jack mounting hole (mm)
+barrel_jack_d = 12.2;     // DC barrel jack mounting hole (mm)
+rj45_w = 16;              // RJ45 panel-mount cutout width (mm)
+rj45_h = 14;              // RJ45 panel-mount cutout height (mm)
+
+// === Derived Dimensions ===
+// Inset variant: PCB drops inside, so box is wider/taller by wall+tolerance on each side
+outer_w = wt32_pcb_w + tolerance * 2 + wall * 2;  // 60 + 0.6 + 5 = 65.6mm
+outer_h = wt32_pcb_h + tolerance * 2 + wall * 2;  // 92 + 0.6 + 5 = 97.6mm
+inner_w = wt32_pcb_w + tolerance * 2;              // 60.6mm — PCB-sized cavity
+inner_h = wt32_pcb_h + tolerance * 2;              // 92.6mm — PCB-sized cavity
+
+// Box internal height — stacked zones from floor up:
+//   1. Carrier standoffs (5mm)
+//   2. Carrier board + components (15mm)
+//   3. Clearance above carrier (4mm)
+//   4. Connector zone for barrel jack / RJ45 bodies (16mm)
+carrier_standoff_h = 5;
+carrier_clearance = 4;
+connector_zone = 16;
+inner_d = carrier_standoff_h + carrier_d + carrier_clearance + connector_zone;
+
+// Total box depth: floor + internal cavity + PCB thickness + screen recess
+// Z=0 floor bottom, Z=wall floor top, Z=wall+inner_d PCB bottom/ledge,
+// Z=wall+inner_d+wt32_pcb_d screen glass, Z=box_d wall top (1mm above glass)
+box_d = wall + inner_d + wt32_pcb_d + screen_recess;  // 2.5 + 40 + 12.1 + 1 = 55.6mm
+
+// Standoff dimensions — inset from PCB bottom to leave room for WT32 PCB posts
+standoff_d = screw_d + 2;  // 5mm — slim to fit within corner walls
+standoff_h = inner_d - wt32_post_h + 0.5 + 25.4*5/16;  // +5/16" per test ring print fit
+
+// Panel-mount hole height — all ports centered at same Z, slightly above midpoint
+port_z = wall + inner_d / 2 + 1.5;  // ~24mm — just above center of box
+
+// WT32 mounting positions (relative to enclosure center XY)
+wt32_mount = [
+    [ (wt32_pcb_w/2 - wt32_hole_inset_w),  (wt32_pcb_h/2 - wt32_top_inset_h)],    // top-right (corner)
+    [-(wt32_pcb_w/2 - wt32_hole_inset_w),  (wt32_pcb_h/2 - wt32_top_inset_h)],    // top-left (corner)
+    [ (wt32_pcb_w/2 - wt32_hole_inset_w), -(wt32_pcb_h/2 - wt32_bot_inset_h)],    // bottom-right (inset)
+    [-(wt32_pcb_w/2 - wt32_hole_inset_w), -(wt32_pcb_h/2 - wt32_bot_inset_h)]     // bottom-left (inset)
+];
+
+// Carrier board mounting positions (4 corners of 50x70mm board)
+carrier_inset = 3;
+carrier_mount = [
+    [ (carrier_w/2 - carrier_inset),  (carrier_h/2 - carrier_inset)],
+    [-(carrier_w/2 - carrier_inset),  (carrier_h/2 - carrier_inset)],
+    [ (carrier_w/2 - carrier_inset), -(carrier_h/2 - carrier_inset)],
+    [-(carrier_w/2 - carrier_inset), -(carrier_h/2 - carrier_inset)]
+];
+
+// Kickstand dimensions (recalculated for new outer_h)
+ks_w = 25;
+ks_h = outer_h * 0.65;
+ks_thick = 3;
+ks_hinge_d = 5;
+ks_hinge_slot_w = ks_w + 1;
+
+// $fn for curves
+$fn = 40;
+
+// ============================================================
+// Utility Modules
+// ============================================================
+
+module rounded_rect_2d(w, h, r) {
+    offset(r = r)
+        square([w - 2*r, h - 2*r], center = true);
+}
+
+module rounded_box(w, h, d, r) {
+    linear_extrude(height = d)
+        rounded_rect_2d(w, h, r);
+}
+
+module vent_slot(length, width, depth) {
+    translate([-length/2, -width/2, 0])
+        cube([length, width, depth + 1]);
+}
+
+// ============================================================
+// Part 1: Inset Box
+// ============================================================
+
+module inset_box() {
+    difference() {
+        union() {
+            // Outer walls with floor — full height including PCB zone
+            difference() {
+                rounded_box(outer_w, outer_h, box_d, corner_r);
+                translate([0, 0, wall])
+                    rounded_box(inner_w, inner_h, box_d, max(corner_r - wall, 1));
+            }
+
+            // WT32 mounting standoffs — same as flush version
+            // Start 0.01 below floor top to avoid coincident faces
+            for (pos = wt32_mount) {
+                translate([pos[0], pos[1], wall - 0.01])
+                    cylinder(d = standoff_d + 0.02, h = standoff_h + 0.01);
+            }
+
+            // Buttress ribs — connect each standoff to nearest side wall
+            for (pos = wt32_mount) {
+                sx = pos[0] > 0 ? 1 : -1;
+                bx = sx * (inner_w/2 + 0.5);  // 0.5mm into wall for solid union
+                translate([min(pos[0], bx), pos[1] - standoff_d/2, wall - 0.01])
+                    cube([abs(bx - pos[0]), standoff_d, standoff_h + 0.01]);
+            }
+
+            // Carrier board standoffs (shorter, near floor)
+            for (pos = carrier_mount) {
+                translate([pos[0], pos[1], wall - 0.01])
+                    cylinder(d = screw_d + 2.5, h = carrier_standoff_h + 0.01);
+            }
+        }
+
+        // --- WT32 through-holes (bottom to top) ---
+        // M3 screws from below, through floor and standoff, into PCB posts
+        for (pos = wt32_mount) {
+            // Screw shaft — all the way through
+            translate([pos[0], pos[1], -0.5])
+                cylinder(d = screw_d, h = box_d + 1);
+            // Counterbore for screw head flush with bottom
+            translate([pos[0], pos[1], -0.5])
+                cylinder(d = screw_head_d, h = screw_head_recess + 0.5);
+        }
+
+        // --- Carrier board pilot holes ---
+        for (pos = carrier_mount) {
+            translate([pos[0], pos[1], wall - 0.5])
+                cylinder(d = screw_d * 0.8, h = carrier_standoff_h + 1);
+        }
+
+        // --- Bottom wall: 3x probe jack holes (evenly spaced) ---
+        // Wider inner cavity → recalculate spacing
+        bottom_y = -outer_h/2;
+        probe_spacing = inner_w / 4;   // ~15.25mm — spread across wider wall
+        for (i = [0:2]) {
+            translate([(i - 1) * probe_spacing, bottom_y, port_z])
+                rotate([90, 0, 0])
+                    cylinder(d = probe_jack_d, h = wall * 2 + 1, center = true);
+        }
+
+        // --- Right wall: DC barrel jack + RJ45 Ethernet (same side) ---
+        barrel_y = -15;
+        rj45_y = 15;
+        translate([outer_w/2, barrel_y, port_z])
+            rotate([0, 90, 0])
+                cylinder(d = barrel_jack_d, h = wall * 2 + 1, center = true);
+        translate([outer_w/2, rj45_y, port_z])
+            rotate([0, 90, 0])
+                linear_extrude(height = wall * 2 + 1, center = true)
+                    square([rj45_h, rj45_w], center = true);
+
+        // --- Floor ventilation slots ---
+        vent_count = 5;
+        vent_len = 20;
+        vent_w = 2;
+        vent_spacing = 5;
+        vent_start_y = outer_h/2 - 20;
+
+        for (i = [0 : vent_count - 1]) {
+            translate([-inner_w/4, vent_start_y - i * vent_spacing, -0.5])
+                vent_slot(vent_len, vent_w, wall);
+            translate([inner_w/4, vent_start_y - i * vent_spacing, -0.5])
+                vent_slot(vent_len, vent_w, wall);
+        }
+
+        // No wall pockets needed — inner cavity (60.6mm) gives 0.3mm clearance
+        // from PCB edge to wall on each side. Posts at X=±26 are well clear
+        // of walls at X=±30.3.
+
+        // --- Kickstand hinge slot on floor ---
+        translate([0, -outer_h/2 + ks_h * 0.4 + 10, -0.5])
+            linear_extrude(height = wall + 1)
+                hull() {
+                    translate([-ks_hinge_slot_w/2, 0]) circle(d = ks_hinge_d + 1);
+                    translate([ ks_hinge_slot_w/2, 0]) circle(d = ks_hinge_d + 1);
+                }
+    }
+}
+
+// ============================================================
+// Part 2: Kickstand
+// ============================================================
+
+module kickstand() {
+    hinge_r = ks_hinge_d / 2;
+
+    difference() {
+        union() {
+            translate([-ks_w/2, 0, 0])
+                cube([ks_w, ks_h, ks_thick]);
+
+            translate([-ks_w/2 + hinge_r, 0, ks_thick/2])
+                rotate([0, 90, 0])
+                    cylinder(r = hinge_r, h = ks_w - ks_hinge_d);
+        }
+
+        translate([-ks_w/2 - 0.5, -hinge_r, ks_thick/2 - 0.4])
+            cube([ks_w + 1, 1.5, 0.8]);
+    }
+
+    translate([-ks_w/2, ks_h - 1, 0])
+        cube([ks_w, 1, ks_thick + 1.5]);
+}
+
+// ============================================================
+// Part 3: Test Ring (top slice — standoffs + PCB pocket for fitment)
+// ============================================================
+
+module test_ring() {
+    ring_h = 15;  // Slim ring: ~4mm standoff + PCB pocket + screen lip
+    translate([0, 0, -(box_d - ring_h)])
+        intersection() {
+            inset_box();
+            translate([-outer_w, -outer_h, box_d - ring_h])
+                cube([outer_w * 2, outer_h * 2, ring_h]);
+        }
+}
+
+// ============================================================
+// Part Selector
+// ============================================================
+
+if (part == "box") {
+    inset_box();
+}
+else if (part == "kickstand") {
+    kickstand();
+}
+else if (part == "test_ring") {
+    test_ring();
+}
+else {
+    // "all" — arranged for visualization
+    inset_box();
+
+    translate([outer_w + 15, -outer_h/2 + 10, 0])
+        kickstand();
+}