Redesign MCU and PCB mounting

model/pointer.FCMacro

@@ -1,430 +1,190 @@
 """
-IMU Pointer Enclosure  —  v6
+IMU Pointer Enclosure — v11.7 (Slimmed Corners & Rounded USB-C)
-============================
-Fixes from v5 (diagnosed from rendered images):
-
-  1. BOTTOM HOLE:
-     v5 built the bottom shell from a full-height box (0→H) then trimmed
-     at SPLIT_Z. The taper wedge interacted badly with the split cut near
-     X=0 leaving a hole in the floor. Fix: build bottom outer solid only
-     to SPLIT_Z height — no trimming step needed, no interaction.
-
-  2. TOP SHELL WALLS PROTRUDING BELOW SPLIT:
-     v5 top_outer started at SPLIT_Z but the cavity inside started at
-     SPLIT_Z + WALL, leaving WALL=3.5mm of solid wall below the groove —
-     visually protruding past the bottom shell. Fix: the top shell outer
-     solid starts at SPLIT_Z. The groove is cut starting exactly at SPLIT_Z
-     so there is zero protrusion below the split line.
-
-  3. BUTTON CAP NOT FLUSH / SITTING PROUD:
-     Aperture cylinder had arithmetic-derived Z that could miss the top wall
-     faces after filleting. Fix: aperture runs from Z=SPLIT_Z (well inside
-     the cavity) all the way to Z=H+2 — brute-force punch, impossible to miss.
-
-  4. CAP RIM SITS UNDER OUTER FACE (not above it):
-     Cap is placed so shaft top = H (flush). Rim hangs BELOW the top face
-     inside the cavity — correct retention geometry. The cap shaft top is
-     exactly flush with H. No part of the cap protrudes above H.
-
-Split joint design:
-  - Bottom shell has a TONGUE that projects UP from SPLIT_Z.
-    The tongue is a thin rectangular frame (inner perimeter of the walls).
-  - Top shell has a matching GROOVE cut into the inside of its lower edge,
-    starting exactly at SPLIT_Z (the bottom face of the top shell).
-  - Two flex notches cut through the tongue on the long sides allow snap fit.
 """
 
 import FreeCAD as App
 import FreeCADGui as Gui
 import Part
-import math
 from FreeCAD import Base
 
-doc = App.newDocument("pointer_v7")
+doc = App.newDocument("pointer_v11_7")
 
-# ─────────────────────────────────────────────────────────────────────────────
+# ─── DIMENSIONS ───────────────────────────────────────────────────────────────
-#  DIMENSIONS
+L, W, H = 115.0, 36.0, 22.0
-# ─────────────────────────────────────────────────────────────────────────────
+WALL = 3.5
-L    = 115.0   # length (X): front=0, back=L
+CR, CR_I = 8.0, 4.5
-W    = 36.0    # width  (Y)
+TOL = 0.25 
-H    = 22.0    # height (Z): bottom=0, top=H
+EDGE_FILLET = 3.0
-WALL = 4.5     # wall thickness (+1 mm vs v6 — closes taper floor gap)
-CR   = 5.0     # corner fillet radius (vertical edges)
-TOL  = 0.25    # fit tolerance
 
-# Taper: front of bottom shell is TAPER_RISE mm shorter than back.
+USBC_W, USBC_H, USBC_Z = 12.0, 7.0, 5.0 
-# Applied only to the BOTTOM shell (it's where the ergonomic taper lives).
+SPLIT_Z = USBC_Z + USBC_H + 2.5 
-TAPER_RISE = 0.0    # no taper — removed per user request
-TAPER_LEN  = 100.0  # unused but kept to avoid NameError
 
-# Split plane
+# MICRO-DETENT Snap Logic
-USBC_W  = 11.0
+TONGUE_H, TONGUE_T = 2.5, 2.0
-USBC_H  =  7.0
+GROOVE_H, GROOVE_T = TONGUE_H + TOL, TONGUE_T + TOL
-USBC_Z  =  5.0
+RIDGE_W = 12.0
-SPLIT_Z = USBC_Z + USBC_H + 2.5   # = 14.5 mm
+RIDGE_H = 1.2      
+RIDGE_PROUD = 1.0  # Snap ridge protrusion
+RIDGE_Z_OFF = (TONGUE_H - RIDGE_H) / 2.0
 
-# Tongue/groove clip joint
+# ─── IMU BOARD (+1mm Spacing & Slim Corners) ──────────────────────────────────
-TONGUE_H = 2.5   # how far tongue projects above SPLIT_Z
+PCB_T, BRD_L, BRD_W = 3.0, 22.6, 19.6
-TONGUE_T = 1.2   # tongue wall thickness
+BRD_X, BRD_Y = WALL, (W - BRD_W) / 2.0
-GROOVE_H = TONGUE_H + TOL
+PLATFORM_H, MIC_EXTRA = 1.5, 2.0
-GROOVE_T = TONGUE_T + TOL
+MIC_PCB_T = 2.5          # Thicker PCB section (MEMS mic), rounded up from 2.2
-
+BUMP_PROUD = 0.3         # Press-fit nub protrusion into board cavity
-# Flex notch through tongue (for snap release)
+BUMP_R = 0.6             # Nub radius (half-sphere)
-NOTCH_W  = 8.0
-NOTCH_H  = TONGUE_H + 0.5
-
-# ─────────────────────────────────────────────────────────────────────────────
-#  IMU BOARD
-# ─────────────────────────────────────────────────────────────────────────────
-PCB_T      = 1.0
-BRD_L      = 21.0
-BRD_W      = 17.5
-BRD_X      = WALL
-BRD_Y      = (W - BRD_W) / 2.0
-PLATFORM_H = 0.5
 BRD_Z = WALL + PLATFORM_H
-ARM_LEN    = 5.0
-ARM_THICK  = 1.6
-ARM_H      = BRD_Z + PCB_T + 0.8
-CLIP_TOL   = 0.35
 
-# ─────────────────────────────────────────────────────────────────────────────
+# ─── BUTTON & BATTERY ─────────────────────────────────────────────────────────
-#  BATTERY BAY
+BAT_L, BAT_W, BAT_H = 50.0, 12.0, 12.0
-# ─────────────────────────────────────────────────────────────────────────────
+BAT_X, BAT_Y = BRD_X + BRD_L + 8.0 + 5.0, (W - BAT_W) / 2.0
-BAT_L      = 50.0
-BAT_W      = 12.0
-BAT_H      = 12.0
-BAT_X      = BRD_X + BRD_L + 8.0
-BAT_Y      = (W - BAT_W) / 2.0
 BAT_CLIP_Y = 8.0
+BTN_X, BTN_CY, BTN_HOLE_R = 28.0, W / 2.0, 10.0
+CAP_SHAFT_R, CAP_SHAFT_H = 9.6, WALL
+CAP_RIM_R, CAP_RIM_H = 12.0, 1.5
+NUBBIN_R, NUBBIN_H = 4.2, 1.0
+BTN_DOME_R, BTN_DOME_SAG = 14.0, 0.6
 
-# ─────────────────────────────────────────────────────────────────────────────
+PCB_BOT_Z = SPLIT_Z + 1.5
-#  BUTTON
+POST_H = BRD_Z + PCB_T + MIC_EXTRA + 3.0 - 4.0  # Lowered 4mm for button PCB + button thickness
-# ─────────────────────────────────────────────────────────────────────────────
+POST_OFFS_X, POST_OFFS_Y = 4.0, 11.0
-BTN_X       = 28.0
+LH_R, LH_X, LH_Y_OFFS = 1.5, L - WALL - 3.0, 4.0
-BTN_CY      = W / 2.0
+BPCB_L, BPCB_W = 16.0, 16.0
-BTN_HOLE_R  = 8.0
-CAP_SHAFT_R = BTN_HOLE_R - 0.4   # 0.4 mm radial clearance in hole
-CAP_SHAFT_H = WALL                # shaft fills top wall → top face flush
-CAP_RIM_R   = BTN_HOLE_R + 2.0   # 2 mm wider than hole → retention
-CAP_RIM_H   = 1.5
-NUBBIN_R    = 1.8
-NUBBIN_H    = 2.0
 
-# Switch geometry (adjust to match your Omron)
+# ─── HELPERS ──────────────────────────────────────────────────────────────────
-SWITCH_BODY_H = 5.0
-STEM_H        = 2.5
-GAP           = 0.5
 
-# PCB position derived top-down
+def box(lx, ly, lz, ox=0, oy=0, oz=0):
-PCB_TOP_Z = H - WALL - CAP_RIM_H - NUBBIN_H - GAP - SWITCH_BODY_H - STEM_H
-PCB_BOT_Z = PCB_TOP_Z - PCB_T
-# Clamp: must be inside the top shell cavity
-floor_top_shell = SPLIT_Z + WALL
-if PCB_BOT_Z < floor_top_shell + 0.5:
-    PCB_BOT_Z = floor_top_shell + 0.5
-    PCB_TOP_Z = PCB_BOT_Z + PCB_T
-
-POST_H   = PCB_BOT_Z - floor_top_shell
-POST_OD  = 4.0;  POST_R  = POST_OD / 2.0
-POST_ID  = 1.9;  POST_IR = POST_ID / 2.0
-POST_SEP = 3.0
-
-BPCB_L     = 16.0
-BPCB_W     = 16.0
-SHELF_WALL = 2.0
-
-# ─────────────────────────────────────────────────────────────────────────────
-#  HELPERS
-# ─────────────────────────────────────────────────────────────────────────────
-
-def box(lx, ly, lz, ox=0.0, oy=0.0, oz=0.0):
     return Part.makeBox(lx, ly, lz, Base.Vector(ox, oy, oz))
 
-def cyl(r, h, cx=0.0, cy=0.0, cz=0.0):
+def rbox(lx, ly, lz, ox=0, oy=0, oz=0, r=CR):
+    b = box(lx, ly, lz, ox, oy, oz)
+    try:
+        edges = [e for e in b.Edges if abs(e.Vertexes[0].X - e.Vertexes[1].X) < 1e-3 and abs(e.Vertexes[0].Y - e.Vertexes[1].Y) < 1e-3]
+        return b.makeFillet(r, edges) if edges else b
+    except: return b
+
+def cyl(r, h, cx=0, cy=0, cz=0):
     return Part.makeCylinder(r, h, Base.Vector(cx, cy, cz))
 
-def rounded_slot(depth, sw, sh, ox, oy, oz):
+def fillet_horiz(solid, r, z_test):
-    """Stadium slot extruded in +X."""
-    r  = min(sh / 2.0, sw / 2.0)
-    cy = oy + sw / 2.0
-    cz = oz + sh / 2.0
-    hw = max(sw / 2.0 - r, 0.0)
-    if hw < 1e-6:
-        circ = Part.makeCircle(r, Base.Vector(ox, cy, cz), Base.Vector(1, 0, 0))
-        return Part.Face(Part.Wire(circ)).extrude(Base.Vector(depth, 0, 0))
-    l_s = Base.Vector(ox, cy - hw, cz - r)
-    l_m = Base.Vector(ox, cy - hw - r, cz)
-    l_e = Base.Vector(ox, cy - hw, cz + r)
-    r_s = Base.Vector(ox, cy + hw, cz + r)
-    r_m = Base.Vector(ox, cy + hw + r, cz)
-    r_e = Base.Vector(ox, cy + hw, cz - r)
-    wire = Part.Wire([Part.Arc(l_s, l_m, l_e).toShape(),
-                      Part.makeLine(l_e, r_s),
-                      Part.Arc(r_s, r_m, r_e).toShape(),
-                      Part.makeLine(r_e, l_s)])
-    return Part.Face(wire).extrude(Base.Vector(depth, 0, 0))
-
-def fillet_vert(solid, r, min_len=4.0):
-    """Fillet edges that are primarily vertical (parallel to Z)."""
     try:
-        edges = [e for e in solid.Edges
+        edges = [e for e in solid.Edges if abs(e.Vertexes[0].Z - e.Vertexes[1].Z) < 0.2 and abs((e.Vertexes[0].Z + e.Vertexes[1].Z)/2 - z_test) < 1.5]
-                 if len(e.Vertexes) == 2
+        return solid.makeFillet(r, edges) if edges else solid
-                 and abs(e.Vertexes[0].X - e.Vertexes[1].X) < 1e-3
+    except: return solid
-                 and abs(e.Vertexes[0].Y - e.Vertexes[1].Y) < 1e-3
-                 and e.Length >= min_len]
-        if edges:
-            return solid.makeFillet(r, edges)
-    except Exception as e:
-        print(f"  fillet_vert skipped: {e}")
-    return solid
 
-def make_clip(cx, cy, ix, iy):
+def make_slim_corner(cx, cy, ix, iy):
-    plat_w = ARM_THICK + CLIP_TOL
+    pw = 0.8  # Much slimmer wall thickness (was 1.5/1.6)
-    plat_x = cx if ix > 0 else cx - plat_w
+    sl = 4.0  # Slightly shorter side length
-    plat_y = cy if iy > 0 else cy - plat_w
+    h = PLATFORM_H + PCB_T + 0.5
-    plat   = box(plat_w, plat_w, PLATFORM_H + PCB_T, plat_x, plat_y, WALL)
+    
-    ax_ox  = cx if ix > 0 else cx - ARM_LEN
+    x0, y0 = (cx if ix>0 else cx-sl), (cy if iy>0 else cy-pw)
-    ax_oy  = cy - ARM_THICK - CLIP_TOL if iy > 0 else cy + CLIP_TOL
+    w1 = box(sl, pw, h, x0, y0, WALL)
-    arm_x  = box(ARM_LEN, ARM_THICK, ARM_H, ax_ox, ax_oy, WALL)
+    
-    ay_oy  = cy if iy > 0 else cy - ARM_LEN
+    x1, y1 = (cx if ix>0 else cx-pw), (cy if iy>0 else cy-sl)
-    ay_ox  = cx - ARM_THICK - CLIP_TOL if ix > 0 else cx + CLIP_TOL
+    w2 = box(pw, sl, h, x1, y1, WALL)
-    arm_y  = box(ARM_THICK, ARM_LEN, ARM_H, ay_ox, ay_oy, WALL)
+    
-    cb_w   = ARM_THICK + CLIP_TOL
+    px, py = (cx if ix>0 else cx-sl), (cy if iy>0 else cy-sl)
-    cb_ox  = cx - cb_w if ix > 0 else cx
+    plat = box(sl, sl, PLATFORM_H, px, py, WALL)
-    cb_oy  = cy - cb_w if iy > 0 else cy
+    
-    cb     = box(cb_w, cb_w, ARM_H, cb_ox, cb_oy, WALL)
+    return plat.fuse(w1).fuse(w2)
-    return plat.fuse(arm_x.fuse(arm_y).fuse(cb))
 
 # ═════════════════════════════════════════════════════════════════════════════
-#  BOTTOM SHELL  (Z = 0 → SPLIT_Z, open on top)
+#  CONSTRUCTION
 # ═════════════════════════════════════════════════════════════════════════════
 
-# 1. Outer solid — built ONLY to SPLIT_Z height
+# BOTTOM SHELL
-bot_outer = box(L, W, SPLIT_Z)
+bot_shell = fillet_horiz(rbox(L, W, SPLIT_Z + TONGUE_H), EDGE_FILLET, 0.0)
-bot_outer = fillet_vert(bot_outer, CR, min_len=SPLIT_Z * 0.4)
+bot_shell = bot_shell.cut(rbox(L-WALL*2, W-WALL*2, SPLIT_Z, WALL, WALL, WALL, r=CR_I))
+bot_shell = bot_shell.cut(rbox(L-TONGUE_T*2, W-TONGUE_T*2, TONGUE_H+2, TONGUE_T, TONGUE_T, SPLIT_Z, r=CR-TONGUE_T))
 
-# Fillet the long horizontal edges the user holds.
+# Internal Fusions (Using Slim L-bracket style for MCU)
-# These are the 4 edges running in X at Z≈0 and Z≈SPLIT_Z, on both long sides.
+for cx, cy, ix, iy in [(BRD_X, BRD_Y, 1, 1), (BRD_X+BRD_L, BRD_Y, -1, 1), (BRD_X, BRD_Y+BRD_W, 1, -1), (BRD_X+BRD_L, BRD_Y+BRD_W, -1, -1)]:
-# Same fillet applied to equivalent edges on the top shell later.
+    bot_shell = bot_shell.fuse(make_slim_corner(cx, cy, ix, iy))
-EDGE_FILLET = 2.5   # mm — soft and comfortable, visible but not decorative
+
-try:
+# Press-fit nubs — half-sphere on each L-bracket's inner Y-facing wall (w1)
-    h_edges = []
+bump_z = BRD_Z + 1.0 + BUMP_R           # Bottom of nub sits 1mm above platform
-    for e in bot_outer.Edges:
+pw = 0.8; sl = 4.0                      # Must match make_slim_corner
-        if len(e.Vertexes) != 2:
+for cx, cy, ix, iy in [(BRD_X, BRD_Y, 1, 1), (BRD_X+BRD_L, BRD_Y, -1, 1),
-            continue
+                        (BRD_X, BRD_Y+BRD_W, 1, -1), (BRD_X+BRD_L, BRD_Y+BRD_W, -1, -1)]:
-        v0, v1 = e.Vertexes[0], e.Vertexes[1]
+    # w1 wall centre X: midpoint of the sl-long wall extending from corner
-        dx = abs(v0.X - v1.X)
+    mid_x = cx + ix * sl / 2.0
-        dz = abs(v0.Z - v1.Z)
+    # w1 inner face Y: the face that looks toward the board centre
-        dy = abs(v0.Y - v1.Y)
+    face_y = cy if iy > 0 else cy - pw  # wall origin Y
-        # Long edge in X, horizontal, on a long side face —
+    inner_y = face_y + pw if iy > 0 else face_y  # the side facing inward
-        # but ONLY at Z≈0 (bottom face). Exclude Z≈SPLIT_Z (the join edge).
+    # iy>0 → bump faces +Y (inward), iy<0 → bump faces -Y (inward)
-        z_mid = (v0.Z + v1.Z) / 2.0
+    # Actually: iy>0 means corner is at low-Y side, wall inner face = face_y+pw, bump goes +Y
-        if dx > L * 0.5 and dz < 0.5 and dy < 0.5 and z_mid < 1.0:
+    #           iy<0 means corner is at high-Y side, wall inner face = face_y, bump goes -Y
-            h_edges.append(e)
+    sph = Part.makeSphere(BUMP_R, Base.Vector(mid_x, inner_y, bump_z))
-    if h_edges:
+    cs = BUMP_R + 0.5
-        bot_outer = bot_outer.makeFillet(EDGE_FILLET, h_edges)
+    # Clip: keep only the half protruding inward (toward board centre)
-        print(f"Bottom shell: filleted {len(h_edges)} horizontal edge(s) R={EDGE_FILLET}")
+    if iy > 0:
+        clip = box(cs*2, cs, cs*2, mid_x - cs, inner_y, bump_z - cs)
     else:
-        print("Bottom shell: no horizontal edges found — skipped")
+        clip = box(cs*2, cs, cs*2, mid_x - cs, inner_y - cs, bump_z - cs)
-except Exception as exc:
+    half_sph = sph.common(clip)
-    print(f"Bottom shell horizontal fillet skipped: {exc}")
+    bot_shell = bot_shell.fuse(half_sph)
 
-# No taper wedge — removed per user request
+POST_R = 1.75
+POST_TAPER_EXTRA = 0.3    # Extra radius at base
+POST_TAPER_H = 6.0        # Height over which the taper blends to nominal radius
+for px, py in [(BTN_X+ox, BTN_CY+oy) for ox in [-POST_OFFS_X, POST_OFFS_X] for oy in [-POST_OFFS_Y, POST_OFFS_Y]]:
+    post = cyl(POST_R, POST_H, px, py, WALL)
+    # Tapered cone base: wider at bottom, blends to post radius at POST_TAPER_H
+    taper = Part.makeCone(POST_R + POST_TAPER_EXTRA, POST_R, POST_TAPER_H,
+                          Base.Vector(px, py, WALL))
+    post = post.fuse(taper)
+    post = post.cut(cyl(0.5, POST_H + 1, px, py, WALL))
+    bot_shell = bot_shell.fuse(post)
 
-# 3. Inner cavity — floor at WALL, ceiling at SPLIT_Z (open top, no ceiling)
+# Rounded USB-C Cut (Pill Shape)
-bot_cav_lx = L - WALL * 2
+usbc_r = USBC_H / 2.0
-bot_cav_ly = W - WALL * 2
+usbc_box = box(WALL*4, USBC_W - 2*usbc_r, USBC_H, -1, W/2 - USBC_W/2 + usbc_r, USBC_Z)
-bot_cav_lz = SPLIT_Z - WALL   # floor(WALL) → SPLIT_Z
+usbc_cyl1 = Part.makeCylinder(usbc_r, WALL*4, Base.Vector(-1, W/2 - USBC_W/2 + usbc_r, USBC_Z + usbc_r), Base.Vector(1, 0, 0))
-bot_inner  = box(bot_cav_lx, bot_cav_ly, bot_cav_lz, WALL, WALL, WALL)
+usbc_cyl2 = Part.makeCylinder(usbc_r, WALL*4, Base.Vector(-1, W/2 + USBC_W/2 - usbc_r, USBC_Z + usbc_r), Base.Vector(1, 0, 0))
-bot_shell  = bot_outer.cut(bot_inner)
+usbc_rounded = usbc_box.fuse(usbc_cyl1).fuse(usbc_cyl2)
+bot_shell = bot_shell.cut(usbc_rounded)
 
-# 4. Tongue (projects UP from SPLIT_Z, inner perimeter frame)
+# Battery bay + retaining tabs
-#    Outer edge of tongue = inner face of outer wall = WALL from outside
-#    Inner edge of tongue = WALL + TONGUE_T from outside
-t_slab = box(bot_cav_lx,          bot_cav_ly,          TONGUE_H,
-             WALL,                 WALL,                 SPLIT_Z)
-t_cut  = box(bot_cav_lx - TONGUE_T*2, bot_cav_ly - TONGUE_T*2, TONGUE_H + 1,
-             WALL + TONGUE_T,     WALL + TONGUE_T,     SPLIT_Z - 0.5)
-tongue = t_slab.cut(t_cut)
-
-# Flex notches on the two long sides (parallel to X)
-nx0 = L / 2.0 - NOTCH_W / 2.0
-for ny_start in [WALL, W - WALL - TONGUE_T]:
-    tongue = tongue.cut(
-        box(NOTCH_W, TONGUE_T + 0.5, NOTCH_H,
-            nx0, ny_start - 0.1, SPLIT_Z - 0.1))
-bot_shell = bot_shell.fuse(tongue)
-
-# 5. IMU clips
-for cx, cy, ix, iy in [
-    (BRD_X,         BRD_Y,         +1, +1),
-    (BRD_X + BRD_L, BRD_Y,         -1, +1),
-    (BRD_X,         BRD_Y + BRD_W, +1, -1),
-    (BRD_X + BRD_L, BRD_Y + BRD_W, -1, -1),
-]:
-    bot_shell = bot_shell.fuse(make_clip(cx, cy, ix, iy))
-
-# 6. USB-C slot — starts at X = -WALL*3 so it punches through the rounded
-#    front face cleanly regardless of fillet radius
-bot_shell = bot_shell.cut(
-    rounded_slot(WALL * 6, USBC_W, USBC_H,
-                 -WALL * 3,
-                 W / 2.0 - USBC_W / 2.0,
-                 USBC_Z))
-
-# 7. Battery bay
 bot_shell = bot_shell.cut(box(BAT_L, BAT_W, 3.0, BAT_X, BAT_Y, WALL))
-cy0 = BAT_Y + BAT_W / 2.0 - BAT_CLIP_Y / 2.0
+bat_clip_cy = BAT_Y + BAT_W / 2.0 - BAT_CLIP_Y / 2.0
-bot_shell = bot_shell.fuse(box(2.0, BAT_CLIP_Y, BAT_H * 0.55, BAT_X - 2.0,   cy0, WALL))
+bot_shell = bot_shell.fuse(box(2.0, BAT_CLIP_Y, BAT_H * 0.55, BAT_X - 2.0,   bat_clip_cy, WALL))
-bot_shell = bot_shell.fuse(box(2.0, BAT_CLIP_Y, BAT_H * 0.55, BAT_X + BAT_L, cy0, WALL))
+bot_shell = bot_shell.fuse(box(2.0, BAT_CLIP_Y, BAT_H * 0.55, BAT_X + BAT_L, bat_clip_cy, WALL))
 
-# ═════════════════════════════════════════════════════════════════════════════
+# MICRO-DETENT RIDGES: Buried deep, barely protruding
-#  TOP SHELL  (Z = SPLIT_Z → H, open on bottom, closed ceiling at H)
+rx0, rz0 = L/2 - RIDGE_W/2, SPLIT_Z + RIDGE_Z_OFF
-# ═════════════════════════════════════════════════════════════════════════════
+ridge_bury = 1.5 
-top_h = H - SPLIT_Z   # = 7.5 mm
+ridge_total_t = ridge_bury + RIDGE_PROUD
+bot_shell = bot_shell.fuse(box(RIDGE_W, ridge_total_t, RIDGE_H, rx0, TONGUE_T - ridge_bury, rz0))
+bot_shell = bot_shell.fuse(box(RIDGE_W, ridge_total_t, RIDGE_H, rx0, W - TONGUE_T - RIDGE_PROUD, rz0))
 
-# 1. Outer solid spans SPLIT_Z → H
+# TOP SHELL
-top_outer = box(L, W, top_h, 0, 0, SPLIT_Z)
+top_shell = fillet_horiz(rbox(L, W, H-SPLIT_Z, 0, 0, SPLIT_Z), EDGE_FILLET, H)
-top_outer = fillet_vert(top_outer, CR, min_len=top_h * 0.4)
+top_shell = top_shell.cut(rbox(L-WALL*2, W-WALL*2, H-SPLIT_Z-WALL, WALL, WALL, SPLIT_Z, r=CR_I))
 
-# Fillet the long horizontal edges of the top shell —
+# Groove and Matching Recesses
-# the top edges (Z≈H) are the ones selected in blue in the user's screenshot.
+g_band = rbox(L, W, GROOVE_H, 0, 0, SPLIT_Z, r=CR).cut(rbox(L-GROOVE_T*2, W-GROOVE_T*2, GROOVE_H+2, GROOVE_T, GROOVE_T, SPLIT_Z-1, r=CR-GROOVE_T))
-try:
+top_shell = top_shell.cut(g_band)
-    th_edges = []
-    for e in top_outer.Edges:
-        if len(e.Vertexes) != 2:
-            continue
-        v0, v1 = e.Vertexes[0], e.Vertexes[1]
-        dx = abs(v0.X - v1.X)
-        dz = abs(v0.Z - v1.Z)
-        dy = abs(v0.Y - v1.Y)
-        # Long edge in X, horizontal, on a long side face —
-        # ONLY at Z≈H (top face). Exclude Z≈SPLIT_Z (the join edge).
-        z_mid = (v0.Z + v1.Z) / 2.0
-        if dx > L * 0.5 and dz < 0.5 and dy < 0.5 and z_mid > H - 1.0:
-            th_edges.append(e)
-    if th_edges:
-        top_outer = top_outer.makeFillet(EDGE_FILLET, th_edges)
-        print(f"Top shell: filleted {len(th_edges)} horizontal edge(s) R={EDGE_FILLET}")
-    else:
-        print("Top shell: no horizontal edges found — skipped")
-except Exception as exc:
-    print(f"Top shell horizontal fillet skipped: {exc}")
 
-# 2. Inner cavity: side walls WALL thick, CEILING at H-WALL (WALL-thick roof),
+# Recesses in groove wall — bottom ridges click into these
-#    FLOOR open (starts at SPLIT_Z — nothing blocks the bottom opening).
+rec_w = RIDGE_W + TOL*2
-#    Cavity box: X from WALL→L-WALL, Y from WALL→W-WALL, Z from SPLIT_Z→H-WALL
+rec_d = RIDGE_PROUD + TOL  # Slightly deeper than ridge protrusion
-top_cav_lx = L - WALL * 2
+top_shell = top_shell.cut(box(rec_w, rec_d, RIDGE_H+TOL, L/2-rec_w/2, GROOVE_T, rz0-TOL/2))
-top_cav_ly = W - WALL * 2
+top_shell = top_shell.cut(box(rec_w, rec_d, RIDGE_H+TOL, L/2-rec_w/2, W-GROOVE_T-rec_d, rz0-TOL/2))
-top_cav_lz = top_h - WALL     # = 7.5 - 3.5 = 4.0 mm interior height
-top_inner  = box(top_cav_lx, top_cav_ly, top_cav_lz,
-                 WALL, WALL, SPLIT_Z)        # starts exactly at SPLIT_Z
-top_shell  = top_outer.cut(top_inner)
 
-# 3. Groove at the bottom of the top shell, starting at SPLIT_Z
+# Button & Cap
-#    The groove is a frame-shaped recess cut into the inner face of the walls.
+top_shell = top_shell.cut(cyl(BTN_HOLE_R, H, BTN_X, BTN_CY, SPLIT_Z))
-#    It goes from Z=SPLIT_Z up to Z=SPLIT_Z+GROOVE_H.
+top_shell = top_shell.cut(Part.makeSphere(BTN_DOME_R, Base.Vector(BTN_X, BTN_CY, H - WALL - BTN_DOME_R + BTN_DOME_SAG)))
-#    Width = GROOVE_T (slightly wider than tongue).
+cap = cyl(CAP_SHAFT_R, CAP_SHAFT_H).fuse(cyl(CAP_RIM_R, CAP_RIM_H, 0, 0, -CAP_RIM_H)).fuse(cyl(NUBBIN_R, NUBBIN_H, 0, 0, -CAP_RIM_H - NUBBIN_H))
-g_slab = box(top_cav_lx, top_cav_ly, GROOVE_H,
+cap_placed = cap.copy(); cap_placed.translate(Base.Vector(BTN_X, BTN_CY, H - CAP_SHAFT_H))
-             WALL, WALL, SPLIT_Z)
-g_cut  = box(top_cav_lx - GROOVE_T*2, top_cav_ly - GROOVE_T*2, GROOVE_H + 1,
-             WALL + GROOVE_T, WALL + GROOVE_T, SPLIT_Z - 0.5)
-groove = g_slab.cut(g_cut)
-top_shell = top_shell.cut(groove)
 
-# 4. Button aperture — brute-force: run cylinder from Z=SPLIT_Z to Z=H+2.
+# ─── REGISTER ────────────────────────────────────────────────────────────────
-#    It will punch through the ceiling regardless of any topology.
+for name, shape, color in [("Shell_Bottom", bot_shell, (0.15, 0.15, 0.18)),
-top_shell = top_shell.cut(
+                           ("Shell_Top", top_shell, (0.25, 0.25, 0.32)),
-    cyl(BTN_HOLE_R, H - SPLIT_Z + 2, BTN_X, BTN_CY, SPLIT_Z))
+                           ("Button_Cap", cap_placed, (0.7, 0.7, 0.7))]:
-
+    obj = doc.addObject("Part::Feature", name)
-# 5. Button PCB shelf frame
+    obj.Shape = shape
-shelf_ox   = BTN_X  - BPCB_L / 2.0
+    obj.ViewObject.ShapeColor = color
-shelf_oy   = BTN_CY - BPCB_W / 2.0
-shelf_h    = 1.5
-shelf_slab = box(BPCB_L + SHELF_WALL*2, BPCB_W + SHELF_WALL*2, shelf_h,
-                 shelf_ox - SHELF_WALL,  shelf_oy - SHELF_WALL,
-                 PCB_BOT_Z - shelf_h)
-shelf_hole = box(BPCB_L, BPCB_W, shelf_h + 2.0,
-                 shelf_ox, shelf_oy, PCB_BOT_Z - shelf_h - 1.0)
-shelf = shelf_slab.cut(shelf_hole)
-if floor_top_shell < PCB_BOT_Z < H - WALL:
-    top_shell = top_shell.fuse(shelf)
-
-# 6. Screw posts on top-shell floor
-if POST_H > 0.5:
-    for py in [BTN_CY - POST_SEP/2.0, BTN_CY + POST_SEP/2.0]:
-        p  = cyl(POST_R,  POST_H,        BTN_X, py, floor_top_shell)
-        ph = cyl(POST_IR, POST_H + 1.0,  BTN_X, py, floor_top_shell)
-        top_shell = top_shell.fuse(p)
-        top_shell = top_shell.cut(ph)
-
-# ═════════════════════════════════════════════════════════════════════════════
-#  BUTTON CAP  (separate printed part)
-#
-#  Geometry at origin:
-#    Shaft:   Z = 0 (bottom/inner) → Z = CAP_SHAFT_H = WALL   (top/flush)
-#    Rim:     Z = -CAP_RIM_H → Z = 0   (hangs inside cavity)
-#    Nubbin:  Z = -CAP_RIM_H-NUBBIN_H → Z = -CAP_RIM_H
-#
-#  Placed so shaft top = H  → flush with top face.
-#  Rim is entirely inside the cavity. No part protrudes above H.
-# ═════════════════════════════════════════════════════════════════════════════
-cap_shaft = cyl(CAP_SHAFT_R, CAP_SHAFT_H)
-cap_rim   = cyl(CAP_RIM_R,   CAP_RIM_H,   0, 0, -CAP_RIM_H)
-cap_nub   = cyl(NUBBIN_R,    NUBBIN_H,    0, 0, -CAP_RIM_H - NUBBIN_H)
-cap_raw   = cap_shaft.fuse(cap_rim).fuse(cap_nub)
-# No fillet on cap top rim — cap sits flush inside aperture so a fillet
-# would create a visible chamfer ring against the hole edge.
-cap_placed = cap_raw.copy()
-cap_placed.translate(Base.Vector(BTN_X, BTN_CY, H - CAP_SHAFT_H))
-
-# ═════════════════════════════════════════════════════════════════════════════
-#  REGISTER OBJECTS
-# ═════════════════════════════════════════════════════════════════════════════
-bot_obj = doc.addObject("Part::Feature", "Shell_Bottom")
-bot_obj.Shape = bot_shell
-bot_obj.ViewObject.ShapeColor   = (0.12, 0.12, 0.14)
-bot_obj.ViewObject.Transparency = 0
-
-top_obj = doc.addObject("Part::Feature", "Shell_Top")
-top_obj.Shape = top_shell
-top_obj.ViewObject.ShapeColor   = (0.20, 0.20, 0.26)
-top_obj.ViewObject.Transparency = 0
-
-cap_obj = doc.addObject("Part::Feature", "Button_Cap")
-cap_obj.Shape = cap_placed
-cap_obj.ViewObject.ShapeColor   = (0.80, 0.80, 0.86)
-cap_obj.ViewObject.Transparency = 0
 
 doc.recompute()
-Gui.activeDocument().activeView().viewIsometric()
 Gui.SendMsgToActiveView("ViewFit")
-
-# ═════════════════════════════════════════════════════════════════════════════
-#  SUMMARY
-# ═════════════════════════════════════════════════════════════════════════════
-print("=" * 62)
-print("IMU Pointer v7")
-print("=" * 62)
-print(f"Body:          {L:.0f} × {W:.0f} mm")
-print(f"Height:        {H:.0f} mm uniform (no taper)")
-print(f"Wall:          {WALL:.1f} mm    CR = {CR:.1f} mm    Edge fillet = {EDGE_FILLET:.1f} mm")
-print(f"Split Z:       {SPLIT_Z:.1f} mm  "
-      f"(USB-C top = {USBC_Z + USBC_H:.1f} mm)")
-print(f"Top shell interior height: {top_cav_lz:.1f} mm  (Z {SPLIT_Z:.1f} → {H - WALL:.1f})")
-print()
-print(f"Tongue H/T:    {TONGUE_H:.1f} / {TONGUE_T:.1f} mm")
-print(f"Groove H/T:    {GROOVE_H:.2f} / {GROOVE_T:.2f} mm")
-print()
-print(f"Button hole:   ⌀{BTN_HOLE_R*2:.0f} mm  X={BTN_X}  Y={BTN_CY:.0f}")
-print(f"Cap shaft:     ⌀{CAP_SHAFT_R*2:.1f} mm × {CAP_SHAFT_H:.1f} mm  (flush, Z {H-WALL:.1f}→{H:.1f})")
-print(f"Cap rim:       ⌀{CAP_RIM_R*2:.0f} mm × {CAP_RIM_H:.1f} mm  (retention, below top face)")
-print()
-print(f"PCB top Z:     {PCB_TOP_Z:.2f} mm  (above split floor {floor_top_shell:.1f} mm)")
-print(f"PCB bot Z:     {PCB_BOT_Z:.2f} mm")
-print(f"Post H:        {POST_H:.2f} mm  ⌀{POST_OD:.0f}/{POST_ID:.1f} mm  sep={POST_SEP:.0f} mm c-to-c")
-print()
-print(f"Switch stack:  body={SWITCH_BODY_H} + stem={STEM_H} + gap={GAP} mm")
-print("  Adjust SWITCH_BODY_H / STEM_H if your Omron differs.")
-print("=" * 62)