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Add parametric 3D-printable enclosure (OpenSCAD)
A printable reimagining of the wooden Kidsbox: rectangular cabinet with two front speakers, removable top lid (NFC tag rests there, reader mounts beneath), and swappable speaker mounts. - kidsbox.scad: master model + part dispatcher (body/lid/speaker_adapter/grill) - params.scad: all tunable dimensions in one place - lib.scad: helper modules (rounded shell, bosses, bolt circles) - Fixed front-panel speaker interface + swappable adapter so any driver fits by printing a new adapter (edit spk_* params, re-export) - Internal mounts: 2x18650 cradle, ESP32-LyraT standoffs, RC522 under lid, 3 buttons on lid, USB/charge + power-switch side ports, back-wall vents - Snap-in speaker grills - Makefile to export STLs and render previews (headless via xvfb) - Exported STLs and preview renders included - Link enclosure from main README Dimensions are sensible defaults from the reference photos and common parts; README flags the fit-critical values to verify before mass-printing. https://claude.ai/code/session_01MhAnh68DPNnTjcKqjNYDmk
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# Kidsbox — 3D-printable enclosure
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A parametric, fully 3D-printable reimagining of the original wooden Kidsbox.
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The design keeps the look of the hand-built box — a rectangular cabinet with two
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front-firing speakers and a removable top where the NFC tag rests — but makes the
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**speaker mount swappable** so you can print an adapter to fit whatever drivers you
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have on hand.
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> Modelled in [OpenSCAD](https://openscad.org). Everything is driven by
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> [`params.scad`](params.scad) — change a few numbers, re-export, and print.
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---
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## What's in the box
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| Part | Qty | File | Notes |
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|---|---|---|---|
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| Body / cabinet | 1 | `stl/body.stl` | Shell with all internal mounts |
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| Lid | 1 | `stl/lid.stl` | Buttons + NFC reader mount underneath |
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| Speaker adapter | 2 | `stl/speaker_adapter.stl` | **Swappable** — print to fit your driver |
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| Speaker grill | 2 | `stl/grill.stl` | Snaps into the sound opening |
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The body carries mounts for everything else:
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- **2× 18650 battery holder** — open-top cradle with retaining lips (`batt_*` params)
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- **ESP32-LyraT v4.3** — four floor standoffs (`lyrat_*` params)
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- **RC522 NFC reader** — pocket on the lid underside, so a tag placed on top reads
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through the thin (`lid_t = 2.4 mm`) PLA window
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- **3 buttons** (vol−, play/pause, vol+) — 12 mm holes in a row near the lid's front edge
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- **Speaker interface** — a fixed bolt pattern the swappable adapters mount to
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- **Side ports** — USB/charging cutout and a power-switch hole
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- **Vents** on the back wall
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| Body | Lid (underside) |
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|---|---|
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|  |  |
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---
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## Printing
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| Setting | Recommendation |
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|---|---|
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| Material | PLA or PETG (PLA is fine; keep metal away from the NFC window) |
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| Layer height | 0.2 mm |
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| Walls / perimeters | 3+ |
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| Infill | 15–20 % |
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| Supports | **Body:** none (print open-side up). **Lid:** none. **Adapter/Grill:** none. |
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| Orientation | Body open-top up; lid top-face down; adapter & grill flat |
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The body is ~190 × 115 × 110 mm, so it fits a 220 × 220 bed (Ender-3 class) and larger.
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---
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## Assembly
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1. **Speakers** → bolt each driver to a `speaker_adapter` using the adapter's inner
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screw holes, then bolt the adapter to the four bosses inside the front wall (M3).
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2. **Grills** → press a `grill` into each sound opening from the front.
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3. **Electronics** → screw the ESP32-LyraT onto the floor standoffs; drop the 18650
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holder into the cradle; route the USB/charge lead to the side cutout.
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4. **NFC reader** → screw the RC522 to the four posts under the lid.
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5. **Buttons** → fit the three 12 mm momentary switches into the lid holes.
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6. **Close up** → lower the lid (the lip locates it) and drive four M3 screws into the
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corner bosses.
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---
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## Swapping speakers (the whole point)
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The front wall never changes — it has a **fixed interface**: a `spk_sound_d` opening
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and four bosses on a `spk_bolt_d` circle. Every speaker bolts to the box through an
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**adapter** that you print to match *your* driver. To make a new adapter, edit the
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adapter block in [`params.scad`](params.scad):
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```scad
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// ---- swappable speaker ADAPTER (edit for YOUR speaker) ----
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spk_frame_d = 66; // your speaker's outer frame diameter
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spk_cutout_d = 58; // cone clearance (a bit less than the cone surround)
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spk_screw_count = 4; // your speaker's mounting-hole count
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spk_screw_bolt_d = 60; // your speaker's mounting-hole bolt circle
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```
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Then re-export just that part:
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```bash
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openscad -D 'part="speaker_adapter"' -o stl/speaker_adapter.stl kidsbox.scad
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```
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Leave the `spk_sound_d` / `spk_bolt_d` (panel) values alone and your new adapter will
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drop straight onto the same box.
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| Speaker adapter (swappable) | Grill |
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|---|---|
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|  |  |
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---
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## Regenerating everything
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```bash
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make stl # export all STLs into stl/
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make img # render preview PNGs (needs a display, or xvfb on a server)
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make all
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```
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Or one part at a time:
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```bash
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openscad -D 'part="body"' -o stl/body.stl kidsbox.scad
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openscad -D 'part="lid"' -o stl/lid.stl kidsbox.scad
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openscad -D 'part="speaker_adapter"' -o stl/speaker_adapter.stl kidsbox.scad
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openscad -D 'part="grill"' -o stl/grill.stl kidsbox.scad
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```
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---
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## ⚠️ Verify before mass-printing
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These dimensions are sensible defaults derived from the reference photos and common
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parts, **not** from calipers on your exact hardware. Before printing the whole set,
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print a quick test of the fit-critical features and confirm against your parts:
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- ESP32-LyraT mounting-hole rectangle (`lyrat_hole_dx`, `lyrat_hole_dy`)
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- RC522 mounting-hole rectangle (`bx`, `by` in the `rc522_mount()` module)
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- Your 18650 holder footprint (`batt_holder_*`)
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- Speaker frame/cone/bolt-circle (`spk_frame_d`, `spk_cutout_d`, `spk_screw_bolt_d`)
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A cheap way to validate the speaker fit is to print one `speaker_adapter` first.
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---
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## Files
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```
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enclosure/
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├── kidsbox.scad master model + part dispatcher
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├── params.scad all tunable dimensions ← edit here
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├── lib.scad helper modules
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├── Makefile export/render targets
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├── stl/ exported STLs
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└── img/ rendered previews
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```
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