LuxLibre

FlashKa Keychain v0.6 housing: files, rebuild, checks (2026-10-16)

Housing 94.4 x 20 x 16 mm, 6061-T6 tray + lid, 2 cells. Source of truth: tools/housing/flashka_housing.py (class P holds every parameter; the build functions and the checks are in the same file). Output: cad/ (STEP, STL, housing_interface.json). Every number and every check result is in chapter 13 (docs/ch13_v0.6_presenter.md, section 13.4) and in the logs in docs/checks/.

1. Files

File	What
cad/FlashKa_tray.step, FlashKa_lid.step	aluminium parts with the skin seams
cad/FlashKa_cap_main.step, FlashKa_cap_slide.step	stainless caps, axis through the origin
cad/FlashKa_tube.step, FlashKa_rf_window, FlashKa_spacer_ring, FlashKa_antenna_spacer	resin parts
cad/FlashKa_print_kit.stl/.step, FlashKa_laser_sleeve	resin kit on sprues (tube, 3 resin caps, spacers, window insert)
cad/FlashKa_tray_drawing.pdf (2 sheets), _lid_, _cap_main_, _cap_slide_, _tube_drawing (.pdf .dxf .png)	A3 drawings, 2:1 (caps and tube 10:1 details)
cad/FlashKa_marking_lid_class2/_class3R/_bottom/_minus_y/_plus_y (.dxf .png)	laser artwork, 1:1
cad/housing_interface.json	parameters + all check results (keys components and pcb_outline are read by the PCB build: do not change)
renders/, assets/v06/	pictures
order_files/2_JLCCNC, 3_JLC3DP	upload files with a README each
docs/checks/housing_v06_*.txt	build log, drawing number table, size comparison

2. Rebuild (from tools/housing/)

python3 flashka_housing.py ../../cad                      # solids + all checks, about 75 s
python3 flashka_marking.py ../../cad ../../cad --tex-dir ../../cad
FK_CACHE=.fk_cache python3 drawings.py ../../cad ../../cad
xvfb-run -a python3 render.py ../../cad ../../renders
python3 render_marking.py ../../cad ../../renders
xvfb-run -a python3 size_comparison.py ../../cad ../../renders
python3 fit_pcb.py ../../cad/FlashKa_main_pcb.step ../../docs/checks    # only when the PCB STEP exists
python3 assemble.py ../../cad ../../cad/FlashKa_main_pcb.step ../../cad

flashka_housing.py --interface-only writes only the JSON (fast). --no-checks skips the slow checks.

3. Design points in short

• Buttons on the bottom face at Y +3.2: SW2 next X 16.4, SW1 main X 23.6, SW3 previous X 30.8. Main cap in a resin light-pipe tube (ring LEDs at X 19.8 and 27.4, lit ring = the end face of the tube, Ø6.0 to Ø8.4). Slide caps sit on the floor.
• Floor RF window 5.1 x 14.0 (X 33.6 to 38.7) closed by a plug on the antenna spacer. S1 is removed.
• Hold-down: two lid bosses with bought pads, both compressed to 0.8 mm: can boss 8.8 x 12.4 x 1.3 + 1.0 mm gap pad; front boss 3.7 x 3.2 x 3.7 next to SW2 + 1.0 mm silicone rubber (Shore A 70).
• Skin: V grooves 0.25 deep. Frames at X 10.2, 30.1, 41, 56, 71, 86 and the V ring at X 3.95; stringers on the sides (Z 3.0, 13.0), lid and bottom (Y +/-3.6). Lid and tray meet in a 0.6 mm rabbet so seams cross the joint on the flat side.
• Marking: SAFE toward the head, ARM toward the tail (armed = knob toward the tail, as in v0.5). The chevrons at X 16.4 (next) point to the head, at X 30.8 (previous) to the tail.

4. Open points

See chapter 13, section 13.9 (hold-down: SW3 over the 0.05 mm limit at 10 N, accepted for v0.6, section 13.4.5) and the layout notes printed by drawings.py. The fit check with the real PCB model passed: docs/checks/fit_pcb_report.txt.

This site is open source. Improve this page.