Hardware resources for the Infinite WiFi Portal.
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README.md

Infinite WiFi Portal

This repository contains the resources used for creating the Infinite WiFi Portal hardware.

Todo: add PCB resources, laser cutting resources, weights and times


Assembly Breakdown

case_exploded

1. Outer Case

  • Fabrication Method: FFF
  • Material: PETG
  • Color: Various
  • Weight: ~24-29g
  • Estimated print time: ~2-3 hours/ea

2. Upper Acrylic

  • Fabrication Method: CO2 laser
  • Material: 3mm acrylic
  • Color: Iridescent coated
  • Weight: tbd
  • Estimated cut time: 20 seconds/ea

3. Upper Isolator

  • Fabrication Method: FFF
  • Material: PETG
  • Color: Matte Black
  • Weight: tbd
  • Estimated print time: tbd

4. LED Ring PCB

  • Assembled by PCB fab
  • 2 layer board
  • Single layer load

5. Lower Isolator

  • Fabrication Method: FFF
  • Material: PETG
  • Color: Matte Black
  • Weight: tbd
  • Estimated print time: tbd

6. Lower Acrylic

  • Fabrication Method: CO2 laser
  • Material: 3mm acrylic
  • Color: Iridescent coated
  • Weight: tbd
  • Estimated cut time: 50 seconds

7. Main PCB

  • Assembled by PCB fab
  • 2 layer board
  • Two layer load (top and bottom)

8. LED Array Grid / Acrylic Curver

  • Fabrication Method: FFF
  • Material: ABS
  • Color: Black
  • Weight: tbd
  • Estimated print time: ~5 minutes/ea

9. Lid (not pictured)

  • Fabrication Method: FFF
  • Material: PETG
  • Color: Various
  • Weight: tbd
  • Estimated print time: ~15 minutes/ea

10. Hanger (not pictured)

  • Fabrication Method: CO2 laser
  • Material: 3mm acrylic
  • Color: Clear
  • Weight: tbd
  • Estimated cut time: 20 seconds

Additional Hardware

  • Lower Acrylic attached to Main PCB using 3x M2.5x5 Phillips screws, 3x M2.5 nuts, 3x M2.5x1 nylon spacer washers
  • Hanger attached to Outer Case with 2x M3x5 or M3x6 flat head machine screws, screwed into M3x3x5 brass heat set inserts

Fabrication equipment used

FFF 3D Printers:

  • 3x Neptune 4 / 4 Pro (production)
  • Bambu Lab X1 Carbon (prototyping)
  • Bambu Lab A1 mini (prototyping)

Laser Cutting:

  • true's China 5070 80W

PCB:

  • Fabbed and assembled by a PCB house