dc32-infinite-wifi-portal/README.md

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# 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
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## Assembly Breakdown
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![case_exploded](image/case_parts_rev2.png)
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#### 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