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