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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

Assembly Breakdown

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