Double click support

model/pointer.FCMacro

@@ -1,430 +1,196 @@
 """
-IMU Pointer Enclosure  —  v6
-============================
-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.
+IMU Pointer Enclosure — v11.7 (Slimmed Corners & Rounded USB-C)
 """
 
 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
-# ─────────────────────────────────────────────────────────────────────────────
-L    = 115.0   # length (X): front=0, back=L
-W    = 36.0    # width  (Y)
-H    = 22.0    # height (Z): bottom=0, top=H
-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
+# ─── DIMENSIONS ───────────────────────────────────────────────────────────────
+L, W, H = 115.0, 36.0, 22.0
+WALL = 3.5
+CR, CR_I = 8.0, 4.5
+TOL = 0.25 
+EDGE_FILLET = 3.0
 
-# Taper: front of bottom shell is TAPER_RISE mm shorter than back.
-# Applied only to the BOTTOM shell (it's where the ergonomic taper lives).
-TAPER_RISE = 0.0    # no taper — removed per user request
-TAPER_LEN  = 100.0  # unused but kept to avoid NameError
+USBC_W, USBC_H, USBC_Z = 12.0, 7.0, 5.0 
+SPLIT_Z = USBC_Z + USBC_H + 2.5 
 
-# Split plane
-USBC_W  = 11.0
-USBC_H  =  7.0
-USBC_Z  =  5.0
-SPLIT_Z = USBC_Z + USBC_H + 2.5   # = 14.5 mm
+# MICRO-DETENT Snap Logic
+TONGUE_H, TONGUE_T = 2.5, 2.0
+GROOVE_H, GROOVE_T = TONGUE_H + TOL, TONGUE_T + TOL
+RIDGE_W = 12.0
+RIDGE_H = 1.2      
+RIDGE_PROUD = 1.0  # Snap ridge protrusion
+RIDGE_Z_OFF = (TONGUE_H - RIDGE_H) / 2.0
 
-# Tongue/groove clip joint
-TONGUE_H = 2.5   # how far tongue projects above SPLIT_Z
-TONGUE_T = 1.2   # tongue wall thickness
-GROOVE_H = TONGUE_H + TOL
-GROOVE_T = TONGUE_T + TOL
+# ─── IMU BOARD (+1mm Spacing & Slim Corners) ──────────────────────────────────
+PCB_T, BRD_L, BRD_W = 3.0, 22.6, 19.6
+BRD_X, BRD_Y = WALL, (W - BRD_W) / 2.0
+PLATFORM_H, MIC_EXTRA = 1.5, 2.0
+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
+BUMP_R = 0.6             # Nub radius (half-sphere)
+BRD_Z = WALL + PLATFORM_H
 
-# Flex notch through tongue (for snap release)
-NOTCH_W  = 8.0
-NOTCH_H  = TONGUE_H + 0.5
+# ─── BUTTON & BATTERY ─────────────────────────────────────────────────────────
+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_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 + 1.0   # +1mm taller shaft so cap sits flush
+CAP_RIM_R, CAP_RIM_H = 12.0, 1.5
+CAP_CAVITY_R, CAP_CAVITY_H = 5.2, 2.5        # Hollow cavity replaces nubbin — clears button dome
+BTN_DOME_R, BTN_DOME_SAG = 14.0, 0.6
 
-# ─────────────────────────────────────────────────────────────────────────────
-#  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
+PCB_BOT_Z = SPLIT_Z + 1.5
+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
+LH_R, LH_X, LH_Y_OFFS = 1.5, L - WALL - 3.0, 4.0
+BPCB_L, BPCB_W = 16.0, 16.0
 
-# ─────────────────────────────────────────────────────────────────────────────
-#  BATTERY BAY
-# ─────────────────────────────────────────────────────────────────────────────
-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
+# ─── HELPERS ──────────────────────────────────────────────────────────────────
 
-# ─────────────────────────────────────────────────────────────────────────────
-#  BUTTON
-# ─────────────────────────────────────────────────────────────────────────────
-BTN_X       = 28.0
-BTN_CY      = W / 2.0
-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)
-SWITCH_BODY_H = 5.0
-STEM_H        = 2.5
-GAP           = 0.5
-
-# PCB position derived top-down
-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):
+def box(lx, ly, lz, ox=0, oy=0, oz=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):
-    """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)."""
+def fillet_horiz(solid, r, z_test):
     try:
-        edges = [e for e in solid.Edges
-                 if len(e.Vertexes) == 2
-                 and abs(e.Vertexes[0].X - e.Vertexes[1].X) < 1e-3
-                 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
+        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]
+        return solid.makeFillet(r, edges) if edges else solid
+    except: return solid
 
-def make_clip(cx, cy, ix, iy):
-    plat_w = ARM_THICK + CLIP_TOL
-    plat_x = cx if ix > 0 else cx - plat_w
-    plat_y = cy if iy > 0 else cy - plat_w
-    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
-    ax_oy  = cy - ARM_THICK - CLIP_TOL if iy > 0 else cy + CLIP_TOL
-    arm_x  = box(ARM_LEN, ARM_THICK, ARM_H, ax_ox, ax_oy, WALL)
-    ay_oy  = cy if iy > 0 else cy - ARM_LEN
-    ay_ox  = cx - ARM_THICK - CLIP_TOL if ix > 0 else cx + CLIP_TOL
-    arm_y  = box(ARM_THICK, ARM_LEN, ARM_H, ay_ox, ay_oy, WALL)
-    cb_w   = ARM_THICK + CLIP_TOL
-    cb_ox  = cx - cb_w if ix > 0 else cx
-    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(arm_x.fuse(arm_y).fuse(cb))
+def make_slim_corner(cx, cy, ix, iy):
+    pw = 0.8  # Much slimmer wall thickness (was 1.5/1.6)
+    sl = 4.0  # Slightly shorter side length
+    h = PLATFORM_H + PCB_T + 0.5
+    
+    x0, y0 = (cx if ix>0 else cx-sl), (cy if iy>0 else cy-pw)
+    w1 = box(sl, pw, h, x0, y0, WALL)
+    
+    x1, y1 = (cx if ix>0 else cx-pw), (cy if iy>0 else cy-sl)
+    w2 = box(pw, sl, h, x1, y1, WALL)
+    
+    px, py = (cx if ix>0 else cx-sl), (cy if iy>0 else cy-sl)
+    plat = box(sl, sl, PLATFORM_H, px, py, WALL)
+    
+    return plat.fuse(w1).fuse(w2)
 
 # ═════════════════════════════════════════════════════════════════════════════
-#  BOTTOM SHELL  (Z = 0 → SPLIT_Z, open on top)
+#  CONSTRUCTION
 # ═════════════════════════════════════════════════════════════════════════════
 
-# 1. Outer solid — built ONLY to SPLIT_Z height
-bot_outer = box(L, W, SPLIT_Z)
-bot_outer = fillet_vert(bot_outer, CR, min_len=SPLIT_Z * 0.4)
+# BOTTOM SHELL
+bot_shell = fillet_horiz(rbox(L, W, SPLIT_Z + TONGUE_H), EDGE_FILLET, 0.0)
+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.
-# These are the 4 edges running in X at Z≈0 and Z≈SPLIT_Z, on both long sides.
-# Same fillet applied to equivalent edges on the top shell later.
-EDGE_FILLET = 2.5   # mm — soft and comfortable, visible but not decorative
-try:
-    h_edges = []
-    for e in bot_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 —
-        # but ONLY at Z≈0 (bottom 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 < 1.0:
-            h_edges.append(e)
-    if h_edges:
-        bot_outer = bot_outer.makeFillet(EDGE_FILLET, h_edges)
-        print(f"Bottom shell: filleted {len(h_edges)} horizontal edge(s) R={EDGE_FILLET}")
+# Internal Fusions (Using Slim L-bracket style for MCU)
+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_slim_corner(cx, cy, ix, iy))
+
+# Press-fit nubs — half-sphere on each L-bracket's inner Y-facing wall (w1)
+bump_z = BRD_Z + 1.0 + BUMP_R           # Bottom of nub sits 1mm above platform
+pw = 0.8; sl = 4.0                      # Must match make_slim_corner
+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)]:
+    # w1 wall centre X: midpoint of the sl-long wall extending from corner
+    mid_x = cx + ix * sl / 2.0
+    # w1 inner face Y: the face that looks toward the board centre
+    face_y = cy if iy > 0 else cy - pw  # wall origin Y
+    inner_y = face_y + pw if iy > 0 else face_y  # the side facing inward
+    # iy>0 → bump faces +Y (inward), iy<0 → bump faces -Y (inward)
+    # Actually: iy>0 means corner is at low-Y side, wall inner face = face_y+pw, bump goes +Y
+    #           iy<0 means corner is at high-Y side, wall inner face = face_y, bump goes -Y
+    sph = Part.makeSphere(BUMP_R, Base.Vector(mid_x, inner_y, bump_z))
+    cs = BUMP_R + 0.5
+    # Clip: keep only the half protruding inward (toward board centre)
+    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")
-except Exception as exc:
-    print(f"Bottom shell horizontal fillet skipped: {exc}")
+        clip = box(cs*2, cs, cs*2, mid_x - cs, inner_y - cs, bump_z - cs)
+    half_sph = sph.common(clip)
+    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
+BACK_POST_SHIFT = POST_R  # Shift back posts by half a post diameter
+for ox in [-POST_OFFS_X, POST_OFFS_X]:
+  for oy in [-POST_OFFS_Y, POST_OFFS_Y]:
+    px = BTN_X + ox + (BACK_POST_SHIFT if ox > 0 else 0)
+    py = BTN_CY + oy
+    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)
-bot_cav_lx = L - WALL * 2
-bot_cav_ly = W - WALL * 2
-bot_cav_lz = SPLIT_Z - WALL   # floor(WALL) → SPLIT_Z
-bot_inner  = box(bot_cav_lx, bot_cav_ly, bot_cav_lz, WALL, WALL, WALL)
-bot_shell  = bot_outer.cut(bot_inner)
+# Rounded USB-C Cut (Pill Shape)
+usbc_r = USBC_H / 2.0
+usbc_box = box(WALL*4, USBC_W - 2*usbc_r, USBC_H, -1, W/2 - USBC_W/2 + usbc_r, USBC_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))
+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))
+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)
-#    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
+# Battery bay + retaining tabs
 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
-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 + BAT_L, cy0, WALL))
+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,   bat_clip_cy, WALL))
+bot_shell = bot_shell.fuse(box(2.0, BAT_CLIP_Y, BAT_H * 0.55, BAT_X + BAT_L, bat_clip_cy, WALL))
 
-# ═════════════════════════════════════════════════════════════════════════════
-#  TOP SHELL  (Z = SPLIT_Z → H, open on bottom, closed ceiling at H)
-# ═════════════════════════════════════════════════════════════════════════════
-top_h = H - SPLIT_Z   # = 7.5 mm
+# MICRO-DETENT RIDGES: Buried deep, barely protruding
+rx0, rz0 = L/2 - RIDGE_W/2, SPLIT_Z + RIDGE_Z_OFF
+ridge_bury = 1.5 
+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_outer = box(L, W, top_h, 0, 0, SPLIT_Z)
-top_outer = fillet_vert(top_outer, CR, min_len=top_h * 0.4)
+# TOP SHELL
+top_shell = fillet_horiz(rbox(L, W, H-SPLIT_Z, 0, 0, SPLIT_Z), EDGE_FILLET, H)
+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 —
-# the top edges (Z≈H) are the ones selected in blue in the user's screenshot.
-try:
-    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}")
+# Groove and Matching Recesses
+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))
+top_shell = top_shell.cut(g_band)
 
-# 2. Inner cavity: side walls WALL thick, CEILING at H-WALL (WALL-thick roof),
-#    FLOOR open (starts at SPLIT_Z — nothing blocks the bottom opening).
-#    Cavity box: X from WALL→L-WALL, Y from WALL→W-WALL, Z from SPLIT_Z→H-WALL
-top_cav_lx = L - WALL * 2
-top_cav_ly = W - WALL * 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)
+# Recesses in groove wall — bottom ridges click into these
+rec_w = RIDGE_W + TOL*2
+rec_d = RIDGE_PROUD + TOL  # Slightly deeper than ridge protrusion
+top_shell = top_shell.cut(box(rec_w, rec_d, RIDGE_H+TOL, L/2-rec_w/2, GROOVE_T, rz0-TOL/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))
 
-# 3. Groove at the bottom of the top shell, starting at SPLIT_Z
-#    The groove is a frame-shaped recess cut into the inner face of the walls.
-#    It goes from Z=SPLIT_Z up to Z=SPLIT_Z+GROOVE_H.
-#    Width = GROOVE_T (slightly wider than tongue).
-g_slab = box(top_cav_lx, top_cav_ly, GROOVE_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)
+# Button & Cap
+top_shell = top_shell.cut(cyl(BTN_HOLE_R, H, BTN_X, BTN_CY, SPLIT_Z))
+top_shell = top_shell.cut(Part.makeSphere(BTN_DOME_R, Base.Vector(BTN_X, BTN_CY, H - WALL - BTN_DOME_R + BTN_DOME_SAG)))
+cap = cyl(CAP_SHAFT_R, CAP_SHAFT_H).fuse(cyl(CAP_RIM_R, CAP_RIM_H, 0, 0, -CAP_RIM_H))
+# Hollow cavity in bottom of shaft — button dome nests inside instead of a protruding nubbin
+cap = cap.cut(cyl(CAP_CAVITY_R, CAP_CAVITY_H, 0, 0, -CAP_RIM_H))
+cap_placed = cap.copy(); cap_placed.translate(Base.Vector(BTN_X, BTN_CY, H - CAP_SHAFT_H))
 
-# 4. Button aperture — brute-force: run cylinder from Z=SPLIT_Z to Z=H+2.
-#    It will punch through the ceiling regardless of any topology.
-top_shell = top_shell.cut(
-    cyl(BTN_HOLE_R, H - SPLIT_Z + 2, BTN_X, BTN_CY, SPLIT_Z))
-
-# 5. Button PCB shelf frame
-shelf_ox   = BTN_X  - BPCB_L / 2.0
-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
+# ─── REGISTER ────────────────────────────────────────────────────────────────
+for name, shape, color in [("Shell_Bottom", bot_shell, (0.15, 0.15, 0.18)),
+                           ("Shell_Top", top_shell, (0.25, 0.25, 0.32)),
+                           ("Button_Cap", cap_placed, (0.7, 0.7, 0.7))]:
+    obj = doc.addObject("Part::Feature", name)
+    obj.Shape = shape
+    obj.ViewObject.ShapeColor = color
 
 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)
+Gui.SendMsgToActiveView("ViewFit")

source/battery.cpp

@@ -36,14 +36,15 @@ void updateBattery() {
   ChargeStatus status = chg ? (pct >= 99 ? CHGSTAT_FULL : CHGSTAT_CHARGING) : CHGSTAT_DISCHARGING;
   // Only write BLE Battery Service when connected - blebas.write() blocks on the
   // SoftDevice ATT layer and causes 30-40ms loop stalls when called during advertising.
-  if (Bluefruit.connected()) blebas.write(pct);
+  if (Bluefruit.connected()) blebas.notify(pct);
   lastChargeStatus = status;
   #ifdef FEATURE_TELEMETRY
     telem.chargeStatus = (uint8_t)status;
   #endif
   const char* st[] = {"discharging","charging","full"};
   Serial.print("[BATT] "); Serial.print(v,2); Serial.print("V ");
-  Serial.print(pct); Serial.print("% "); Serial.println(st[status]);
+  Serial.print(pct); Serial.print("% "); Serial.print(st[status]);
+  Serial.print(" (PIN_CHG="); Serial.print(digitalRead(PIN_CHG)); Serial.println(")");
   // Critical battery alert - only blink when not connected to avoid blocking BLE scheduler.
   // 6 × 160ms = 960ms hard block; skip during active connection.
   if (status == CHGSTAT_DISCHARGING && v < BATT_CRITICAL && !Bluefruit.connected())

source/buttons.cpp

@@ -4,8 +4,18 @@
 #include <bluefruit.h>
 
 extern BLEHidAdafruit blehid;
+extern Config cfg;
 
-static uint8_t physBtnMask = 0;   // bitmask of currently-pressed physical buttons
+static uint8_t physBtnMask = 0;
+static uint8_t rawMaskPrev = 0;
+static unsigned long debounceMs = 0;
+static const unsigned long DEBOUNCE_MS = 20;
+
+// Double-press detection for left button
+static const unsigned long DOUBLE_PRESS_MS = 400;   // max gap between two releases
+static const unsigned long KEY_HOLD_MS     = 60;    // how long to hold the key down
+static unsigned long lastLeftReleaseMs = 0;
+static unsigned long keyDownUntil      = 0;
 
 // Setup 
 void setupPhysicalButtons() {
@@ -36,16 +46,50 @@ void setupPhysicalButtons() {
 void processPhysicalButtons() {
   if (!Bluefruit.connected()) return;
 
-  uint8_t newMask = 0;
-  if (BTN_LEFT_PIN   != BTN_PIN_NONE && digitalRead(BTN_LEFT_PIN)   == LOW) newMask |= MOUSE_BUTTON_LEFT;
-  if (BTN_RIGHT_PIN  != BTN_PIN_NONE && digitalRead(BTN_RIGHT_PIN)  == LOW) newMask |= MOUSE_BUTTON_RIGHT;
-  if (BTN_MIDDLE_PIN != BTN_PIN_NONE && digitalRead(BTN_MIDDLE_PIN) == LOW) newMask |= MOUSE_BUTTON_MIDDLE;
+  unsigned long now = millis();
 
-  if (newMask != physBtnMask) {
+  // Release held key combo after KEY_HOLD_MS
+  if (keyDownUntil && now >= keyDownUntil) {
+    uint8_t noKeys[6] = {};
+    blehid.keyboardReport(0, noKeys);
+    keyDownUntil = 0;
+    Serial.println("[BTN] key release");
+  }
+
+  uint8_t rawMask = 0;
+  if (BTN_LEFT_PIN   != BTN_PIN_NONE && digitalRead(BTN_LEFT_PIN)   == LOW) rawMask |= MOUSE_BUTTON_LEFT;
+  if (BTN_RIGHT_PIN  != BTN_PIN_NONE && digitalRead(BTN_RIGHT_PIN)  == LOW) rawMask |= MOUSE_BUTTON_RIGHT;
+  if (BTN_MIDDLE_PIN != BTN_PIN_NONE && digitalRead(BTN_MIDDLE_PIN) == LOW) rawMask |= MOUSE_BUTTON_MIDDLE;
+
+  if (rawMask != rawMaskPrev) { rawMaskPrev = rawMask; debounceMs = now; }
+  if (rawMask != physBtnMask && (now - debounceMs >= DEBOUNCE_MS)) {
+    uint8_t newMask = rawMask;
+    uint8_t pressed  = newMask & ~physBtnMask;
+    uint8_t released = physBtnMask & ~newMask;
     physBtnMask = newMask;
     if (physBtnMask) blehid.mouseButtonPress(physBtnMask);
     else             blehid.mouseButtonRelease();
-    Serial.print("[BTN] mask=0x"); Serial.println(physBtnMask, HEX);
+    if (pressed & MOUSE_BUTTON_LEFT)    Serial.println("[BTN] L press");
+    if (pressed & MOUSE_BUTTON_RIGHT)   Serial.println("[BTN] R press");
+    if (pressed & MOUSE_BUTTON_MIDDLE)  Serial.println("[BTN] M press");
+    if (released & MOUSE_BUTTON_LEFT) {
+      unsigned long gap = lastLeftReleaseMs ? (now - lastLeftReleaseMs) : 0;
+      Serial.print("[BTN] L release - gap="); Serial.print(gap);
+      Serial.print("ms (max="); Serial.print(DOUBLE_PRESS_MS); Serial.println("ms)");
+      // Double-press detection: two short presses → fire key combo
+      if (lastLeftReleaseMs && (gap <= DOUBLE_PRESS_MS)) {
+        uint8_t keys[6] = {cfg.tapKey, 0, 0, 0, 0, 0};
+        blehid.keyboardReport(cfg.tapMod, keys);
+        keyDownUntil = now + KEY_HOLD_MS;
+        lastLeftReleaseMs = 0;
+        Serial.print("[BTN] Double-press → key 0x"); Serial.print(cfg.tapKey, HEX);
+        Serial.print(" mod 0x"); Serial.println(cfg.tapMod, HEX);
+      } else {
+        lastLeftReleaseMs = now;
+      }
+    }
+    if (released & MOUSE_BUTTON_RIGHT)  Serial.println("[BTN] R release");
+    if (released & MOUSE_BUTTON_MIDDLE) Serial.println("[BTN] M release");
   }
 }
 

source/config.h

@@ -5,7 +5,7 @@
 #define FEATURE_CONFIG_SERVICE
 #define FEATURE_TELEMETRY
 #define FEATURE_IMU_STREAM
-#define FEATURE_TAP_DETECTION
+// #define FEATURE_TAP_DETECTION
 #define FEATURE_TEMP_COMPENSATION
 #define FEATURE_AUTO_RECAL
 #define FEATURE_BATTERY_MONITOR
@@ -60,7 +60,7 @@
 // Physical button pin assignments (hardcoded - set to 0xFF to disable a button)
 // Valid pin numbers: 0-10 (Arduino D0-D10 on XIAO nRF52840 Sense)
 #define BTN_PIN_NONE   0xFF
-#define BTN_LEFT_PIN   BTN_PIN_NONE   // e.g. 0 for D0
+#define BTN_LEFT_PIN   1              // D1, active-low to GND
 #define BTN_RIGHT_PIN  BTN_PIN_NONE   // e.g. 1 for D1
 #define BTN_MIDDLE_PIN BTN_PIN_NONE   // e.g. 2 for D2
 
@@ -158,8 +158,7 @@ struct __attribute__((packed)) ImuPacket {
 static_assert(sizeof(ImuPacket) == 14, "ImuPacket must be 14 bytes");
 #endif
 
-// Tuning constants 
-extern const float ALPHA;
+// Tuning constants
 extern const int   LOOP_RATE_MS;
 extern const int   BIAS_SAMPLES;
 extern const int   IDLE_FRAMES;
@@ -184,10 +183,8 @@ extern const float BATT_CRITICAL;
   extern const unsigned long AUTO_RECAL_MS;
 #endif
 
-// Global state 
-extern float angleX, angleY;
+// Global state
 extern float accumX, accumY;
-extern float gravX, gravY, gravZ;
 extern float biasGX, biasGY, biasGZ;
 extern float calTempC;
 extern float cachedTempC;

source/imu.cpp

@@ -34,9 +34,7 @@ void calibrateGyroBias() {
   biasGY = (float)(sy/BIAS_SAMPLES);
   biasGZ = (float)(sz/BIAS_SAMPLES);
   calTempC = readIMUTemp();
-  angleX = angleY = accumX = accumY = 0.0f;
-  // Seed gravity estimate from current accel so projection is correct immediately
-  gravX = imu.readFloatAccelX(); gravY = imu.readFloatAccelY(); gravZ = imu.readFloatAccelZ();
+  accumX = accumY = 0.0f;
 
   #ifdef FEATURE_TELEMETRY
     statRecalCount++;

source/main.cpp

@@ -17,7 +17,6 @@
 #include "imu.h"
 #include "ble_config.h"
 #include "battery.h"
-#include "tap.h"
 #include "buttons.h"
 #include <bluefruit.h>
 #include <Adafruit_LittleFS.h>
@@ -46,7 +45,7 @@ File cfgFile(InternalFS);
 Config cfg;
 const Config CFG_DEFAULTS = {
   CONFIG_MAGIC, 600.0f, 0.060f, 0.08f, CURVE_LINEAR, 0x00, CHARGE_SLOW,
-  /*tapThreshold=*/12, /*tapAction=*/TAP_ACTION_LEFT, /*tapKey=*/0, /*tapMod=*/0,
+  /*tapThreshold=*/12, /*tapAction=*/TAP_ACTION_KEY, /*tapKey=*/0x04, /*tapMod=*/0x03,  // Ctrl+Shift+A
   /*jerkThreshold=*/2000.0f, /*tapFreezeEnabled=*/1, /*featureFlags=*/FLAG_ALL_DEFAULT
 };
 
@@ -55,11 +54,9 @@ const Config CFG_DEFAULTS = {
 TelemetryPacket telem = {};
 #endif
 
-// Tuning constants 
-const float ALPHA              = 0.96f;
+// Tuning constants
 const int   LOOP_RATE_MS       = 10;
-const float SMOOTH_LOW_RPS     = 0.15f;  // below this → heavy EMA smoothing (~8°/s)
-const float SMOOTH_HIGH_RPS    = 0.50f;  // above this → no smoothing (~29°/s)
+const float SMOOTH_ALPHA       = 0.65f;  // single-pole low-pass for cursor smoothing
 const int   BIAS_SAMPLES       = 200;
 const int   IDLE_FRAMES        = 150;
 const unsigned long BATT_REPORT_MS       = 20000;
@@ -83,11 +80,8 @@ const float BATT_CRITICAL                = 3.10f;
   const unsigned long AUTO_RECAL_MS = 5UL * 60UL * 1000UL;
 #endif
 
-// Global state definitions 
-float angleX = 0, angleY = 0;
+// Global state definitions
 float accumX = 0, accumY = 0;
-// Low-pass filtered gravity estimate in device frame (for roll-independent axis projection)
-float gravX = 0, gravY = 0, gravZ = 1.0f;
 float biasGX = 0, biasGY = 0, biasGZ = 0;
 float calTempC    = 25.0f;
 float cachedTempC = 25.0f;
@@ -121,10 +115,6 @@ bool pendingReset = false;
   bool pendingOTA = false;
 #endif
 
-// Jerk-based shock detection - freeze cursor during tap impacts, doesn't work well yet!
-unsigned long shockFreezeUntil = 0;
-float prevAx = 0, prevAy = 0, prevAz = 0;     // previous frame's accel for Δa
-const unsigned long SHOCK_FREEZE_MS = 80;       // hold freeze after last spike
 
 ChargeStatus lastChargeStatus = CHGSTAT_DISCHARGING;
 
@@ -225,8 +215,6 @@ void setup() {
   #endif
 
   calibrateGyroBias();
-  // Seed previous-accel for jerk detection so first frame doesn't spike
-  prevAx = imu.readFloatAccelX(); prevAy = imu.readFloatAccelY(); prevAz = imu.readFloatAccelZ();
 
   sleepManagerInit();
 
@@ -297,17 +285,19 @@ void loop() {
     }
   #endif
 
-  // Serial commands: 'c' = calibrate, 'r' = factory reset
+  // Serial commands: 'c' = calibrate, 'r' = factory reset, 'd' = axis diagnostic
+  static unsigned long diagUntil = 0;
   while (Serial.available()) {
     char cmd = Serial.read();
     if (cmd == 'c') { Serial.println("[SERIAL] Calibrate"); pendingCal   = true; }
     if (cmd == 'r') { Serial.println("[SERIAL] Reset");     pendingReset = true; }
+    if (cmd == 'd') { Serial.println("[DIAG] Printing raw gyro for 10s — pan, nod, roll one at a time"); diagUntil = now + 10000; }
     #ifdef FEATURE_OTA
       if (cmd == 'o') { Serial.println("[SERIAL] OTA DFU"); pendingOTA = true; }
     #endif
   }
 
-  if (pendingCal)   { pendingCal = false; calibrateGyroBias(); prevAx = imu.readFloatAccelX(); prevAy = imu.readFloatAccelY(); prevAz = imu.readFloatAccelZ(); }
+  if (pendingCal)   { pendingCal = false; calibrateGyroBias(); }
   if (pendingReset) { pendingReset = false; factoryReset(); }
   #ifdef FEATURE_OTA
     if (pendingOTA) {
@@ -371,62 +361,32 @@ void loop() {
     if (cfg.featureFlags & FLAG_TEMP_COMP_ENABLED)
       correction = TEMP_COMP_COEFF_DPS_C * (cachedTempC - calTempC);
   #endif
-  float gx = (imu.readFloatGyroX() - biasGX - correction) * (PI/180.0f);
-  float gy = (imu.readFloatGyroY() - biasGY - correction) * (PI/180.0f);
-  float gz = (imu.readFloatGyroZ() - biasGZ - correction) * (PI/180.0f);
+  float gx = (imu.readFloatGyroX() - biasGX) * (PI/180.0f);             // roll (unused for cursor)
+  float gy = (imu.readFloatGyroY() - biasGY - correction) * (PI/180.0f); // pitch → cursor Y
+  float gz = (imu.readFloatGyroZ() - biasGZ - correction) * (PI/180.0f); // yaw   → cursor X
 
-  float ax = imu.readFloatAccelX();
-  float ay = imu.readFloatAccelY();
-  float az = imu.readFloatAccelZ();
+  // Axis diagnostic — send 'd' over serial to enable
+  if (diagUntil && now < diagUntil) {
+    static unsigned long lastDiagPrint = 0;
+    if (now - lastDiagPrint >= 100) { lastDiagPrint = now;
+      Serial.print("[DIAG] gx="); Serial.print(gx,3);
+      Serial.print(" gy="); Serial.print(gy,3);
+      Serial.print(" gz="); Serial.println(gz,3);
+    }
+  } else if (diagUntil) { diagUntil = 0; Serial.println("[DIAG] Done"); }
 
-  // Jerk-based shock detection - freeze cursor during tap impacts, doesn't work well yet
-  float jx = (ax - prevAx) / dt, jy = (ay - prevAy) / dt, jz = (az - prevAz) / dt;
-  float jerkSq = jx*jx + jy*jy + jz*jz;
-  prevAx = ax; prevAy = ay; prevAz = az;
-  bool shocked = cfg.tapFreezeEnabled && ((jerkSq > cfg.jerkThreshold) || (now < shockFreezeUntil));
-  if (cfg.tapFreezeEnabled && jerkSq > cfg.jerkThreshold) shockFreezeUntil = now + SHOCK_FREEZE_MS;
+  // Direct axis mapping (empirically verified via diagnostic)
+  float yawRate   =  gz;  // gyroZ = pan left/right → cursor X
+  float pitchRate =  gy;  // gyroY = nod up/down    → cursor Y
 
-  // Complementary filter
-  if (shocked) {
-    angleX += gx * dt;
-    angleY += gz * dt;
-  } else {
-    angleX = ALPHA*(angleX + gx*dt) + (1.0f - ALPHA)*atan2f(ax, sqrtf(ay*ay + az*az));
-    angleY = ALPHA*(angleY + gz*dt) + (1.0f - ALPHA)*atan2f(ay, sqrtf(ax*ax + az*az));
-  }
-
-  // Gravity-based axis decomposition
-  const float GRAV_LP = 0.05f;
-  if (!shocked) {
-    gravX += GRAV_LP * (ax - gravX);
-    gravY += GRAV_LP * (ay - gravY);
-    gravZ += GRAV_LP * (az - gravZ);
-  }
-
-  float gN = sqrtf(gravX*gravX + gravY*gravY + gravZ*gravZ);
-  if (gN < 0.3f) gN = 1.0f;
-  float gnx = gravX/gN, gny = gravY/gN, gnz = gravZ/gN;
-
-  float ry = -gnz, rz = gny;
-  float rN = sqrtf(ry*ry + rz*rz);
-  if (rN < 0.01f) { ry = -1.0f; rz = 0.0f; rN = 1.0f; }
-  ry /= rN; rz /= rN;
-
-  // Yaw  (cursor X) = angular velocity component around gravity (vertical)
-  // Pitch (cursor Y) = angular velocity component around screen-right
-  float yawRate   = gx*gnx + gy*gny + gz*gnz;
-  float pitchRate = -(gy*ry + gz*rz);
-
-  // Projected rates amplify residual gyro bias (especially GY drift on pitch axis).
-  float fYaw   = (fabsf(yawRate)   > cfg.deadZone)       ? yawRate   : 0.0f;
-  float fPitch = (fabsf(pitchRate) > cfg.deadZone * 3.0f) ? pitchRate : 0.0f;
+  // Dead zone (equal for both axes)
+  float fYaw   = (fabsf(yawRate)   > cfg.deadZone) ? yawRate   : 0.0f;
+  float fPitch = (fabsf(pitchRate) > cfg.deadZone) ? pitchRate : 0.0f;
 
   #ifdef DEBUG
   { static unsigned long lastDiag = 0;
     if (now - lastDiag >= 500) { lastDiag = now;
-      Serial.print("[PROJ] grav="); Serial.print(gnx,2); Serial.print(","); Serial.print(gny,2); Serial.print(","); Serial.print(gnz,2);
-      Serial.print(" R="); Serial.print(ry,2); Serial.print(","); Serial.print(rz,2);
-      Serial.print(" gyro="); Serial.print(gx,2); Serial.print(","); Serial.print(gy,2); Serial.print(","); Serial.print(gz,2);
+      Serial.print("[IMU] gyro="); Serial.print(gx,2); Serial.print(","); Serial.print(gy,2); Serial.print(","); Serial.print(gz,2);
       Serial.print(" yaw="); Serial.print(yawRate,3); Serial.print(" pitch="); Serial.println(pitchRate,3);
     }
   }
@@ -440,7 +400,7 @@ void loop() {
   #ifdef FEATURE_AUTO_RECAL
     if ((cfg.featureFlags & FLAG_AUTO_RECAL_ENABLED) && idle && idleStartMs != 0 && (now - idleStartMs >= AUTO_RECAL_MS)) {
       Serial.println("[AUTO-CAL] Long idle - recalibrating...");
-      idleStartMs = 0; calibrateGyroBias(); prevAx = imu.readFloatAccelX(); prevAy = imu.readFloatAccelY(); prevAz = imu.readFloatAccelZ(); return;
+      idleStartMs = 0; calibrateGyroBias(); return;
     }
   #endif
 
@@ -449,12 +409,7 @@ void loop() {
 
   static float smoothX = 0.0f, smoothY = 0.0f;
 
-  if (shocked) {
-    // Shock freeze - discard accumulated sub-pixel motion and suppress output
-    smoothX = smoothY = 0.0f;
-    accumX = accumY = 0.0f;
-    flags |= 0x08;  // bit3 = shock freeze active
-  } else if (idle) {
+  if (idle) {
     smoothX = smoothY = 0.0f;
     accumX = accumY = 0.0f;
     flags |= 0x01;
@@ -463,13 +418,9 @@ void loop() {
     float rawY = applyAcceleration(applyCurve(-fPitch * cfg.sensitivity * dt));
     if (cfg.axisFlip & 0x01) rawX = -rawX;
     if (cfg.axisFlip & 0x02) rawY = -rawY;
-    // Tiered velocity smoothing: heavy EMA when nearly still, none when fast.
-    // Thresholds are in rad/s (angular rate), independent of sensitivity setting.
-    float speed = sqrtf(fYaw*fYaw + fPitch*fPitch);
-    float alpha = (speed < SMOOTH_LOW_RPS)  ? 0.25f :
-                  (speed < SMOOTH_HIGH_RPS) ? 0.65f : 1.00f;
-    smoothX = smoothX * (1.0f - alpha) + rawX * alpha;
-    smoothY = smoothY * (1.0f - alpha) + rawY * alpha;
+    // Single-pole low-pass smoothing
+    smoothX = smoothX * (1.0f - SMOOTH_ALPHA) + rawX * SMOOTH_ALPHA;
+    smoothY = smoothY * (1.0f - SMOOTH_ALPHA) + rawY * SMOOTH_ALPHA;
     accumX += smoothX; accumY += smoothY;
     moveX = (int8_t)constrain((int)accumX, -127, 127);
     moveY = (int8_t)constrain((int)accumY, -127, 127);
@@ -485,6 +436,7 @@ void loop() {
       if (now < streamBackoffUntil) {
         // Backing off - host TX buffer congested, skip to avoid 100ms block
       } else {
+        float ax = imu.readFloatAccelX(), ay = imu.readFloatAccelY(), az = imu.readFloatAccelZ();
         ImuPacket pkt;
         pkt.gyroX_mDPS = (int16_t)constrain(gx*(180.f/PI)*1000.f, -32000, 32000);
         pkt.gyroZ_mDPS = (int16_t)constrain(gz*(180.f/PI)*1000.f, -32000, 32000);

source/sleep.cpp

@@ -61,11 +61,16 @@ static void lsmWrite(uint8_t reg, uint8_t val) {
   Wire1.endTransmission();
 }
 
-// ISR 
+// ISR
 static void imuInt1ISR() {
   imuWakeFlag = true;
 }
 
+static volatile bool btnWakeFlag = false;
+static void btnWakeISR() {
+  btnWakeFlag = true;
+}
+
 // Arm wakeup interrupt 
 static void armWakeupInterrupt() {
   lsmWrite(SLP_WAKE_UP_DUR, (uint8_t)((SLEEP_WAKEUP_DUR & 0x03) << 4));
@@ -127,6 +132,15 @@ static void enterImuLP() {
 
   armWakeupInterrupt();
 
+  // Arm button wake interrupt
+  #if BTN_LEFT_PIN != BTN_PIN_NONE
+    btnWakeFlag = false;
+    attachInterrupt(digitalPinToInterrupt(BTN_LEFT_PIN), btnWakeISR, FALLING);
+  #endif
+
+  // Turn off all LEDs for sleep
+  digitalWrite(LED_RED, HIGH); digitalWrite(LED_GREEN, HIGH); digitalWrite(LED_BLUE, HIGH);
+
   lpEnteredMs = millis();
   sleepStage = SLEEP_IMU_LP;
   Serial.print("[SLEEP] IMU LP entered - idle for ");
@@ -153,9 +167,9 @@ static void enterDeepSleep() {
   Serial.println("[SLEEP] Deep sleep - WFE on INT1");
   Serial.flush();
 
-  digitalWrite(LED_RED, LOW); delay(80); digitalWrite(LED_RED, HIGH);
+  digitalWrite(LED_RED, HIGH); digitalWrite(LED_GREEN, HIGH); digitalWrite(LED_BLUE, HIGH);
 
-  while (!imuWakeFlag) {
+  while (!imuWakeFlag && !btnWakeFlag) {
     (void)lsmRead(SLP_WAKE_UP_SRC);
     sd_app_evt_wait();
   }
@@ -172,6 +186,11 @@ void sleepManagerWakeIMU() {
 
   disarmWakeupInterrupt();
 
+  // Detach button wake interrupt — normal polling takes over
+  #if BTN_LEFT_PIN != BTN_PIN_NONE
+    detachInterrupt(digitalPinToInterrupt(BTN_LEFT_PIN));
+  #endif
+
   // Only recalibrate if gyro was off long enough for thermal drift to accumulate,
   // or if waking from full deep sleep. Short LP naps reuse the existing bias.
   unsigned long lpDuration = millis() - lpEnteredMs;
@@ -186,24 +205,9 @@ void sleepManagerWakeIMU() {
   lpEnteredMs   = 0;
 
   // Reset motion filter state to prevent a cursor jump on the first frame.
-  // After sleep: angleX/Y are stale, gravX/Y/Z drifted, accumX/Y is dirty,
-  // and lastTime is old so dt would be huge on the first loop iteration.
-  // Zeroing these here means the first frame integrates 0 motion cleanly.
-  extern float angleX, angleY;
   extern float accumX, accumY;
-  extern float gravX, gravY, gravZ;
-  extern float prevAx, prevAy, prevAz;
   extern unsigned long lastTime;
-  angleX = angleY = 0.0f;
   accumX = accumY = 0.0f;
-  // Reseed gravity from current accel so projection is correct immediately.
-  // Can't call imu.readFloat* here (gyro not fully settled), but accel is
-  // already running - read it directly via Wire1.
-  // Simpler: just reset to neutral [0,0,1] and let the LP filter converge
-  // over the first ~20 frames (200 ms) of real use.
-  gravX = 0.0f; gravY = 0.0f; gravZ = 1.0f;
-  prevAx = 0.0f; prevAy = 0.0f; prevAz = 0.0f;
-  // Set lastTime to now so the first dt = 0 rather than (now - sleepEntryTime)
   lastTime = millis();
 
   sleepStage = SLEEP_AWAKE;
@@ -238,14 +242,23 @@ void sleepManagerInit() {
 // Returns true → caller must skip IMU reads this iteration.
 bool sleepManagerUpdate(unsigned long nowMs, bool idle, bool bleConnected) {
 
-  // ISR wakeup 
+  // ISR wakeup (IMU motion or button press)
+  bool woke = false;
   if (imuWakeFlag) {
     imuWakeFlag = false;
     Serial.print("[SLEEP] INT1 fired - stage="); Serial.println((int)sleepStage);
+    woke = true;
+  }
+  if (btnWakeFlag) {
+    btnWakeFlag = false;
+    Serial.print("[SLEEP] Button fired - stage="); Serial.println((int)sleepStage);
+    woke = true;
+  }
+  if (woke) {
     if (sleepStage == SLEEP_DEEP || sleepStage == SLEEP_IMU_LP) {
       sleepManagerWakeIMU();
     } else {
-      (void)lsmRead(SLP_WAKE_UP_SRC);  // normal-mode edge, clear latch only
+      (void)lsmRead(SLP_WAKE_UP_SRC);
     }
   }
 

source/sleep.h

@@ -11,12 +11,12 @@
 
 // LSM6DS3 wakeup threshold: 1 LSB = 7.8 mg at ±2 g FS (±2g range).
 #ifndef SLEEP_WAKEUP_THS
-  #define SLEEP_WAKEUP_THS   16    // 0–63
+  #define SLEEP_WAKEUP_THS   6    // 0–63
 #endif
 
 // Number of consecutive 26 Hz samples that must exceed the threshold.
 #ifndef SLEEP_WAKEUP_DUR
-  #define SLEEP_WAKEUP_DUR   2    // 0–3
+  #define SLEEP_WAKEUP_DUR   1    // 0–3
 #endif
 
 // GPIO pin connected to LSM6DS3 INT1.

web/app.js

@@ -137,14 +137,11 @@ async function discoverServices() {
     await checkHashMatch();
 
     // Telemetry notify (1 Hz) - also carries chargeStatus
-    chars.telemetry.addEventListener('characteristicvaluechanged', e => parseTelemetry(e.target.value));
-    console.log('[TELEM] subscribing to notifications');
+    chars.telemetry.addEventListener('characteristicvaluechanged', e => {
+      const val = e.target.value;  // capture immediately — Chrome reuses the DataView buffer on next notify
+      parseTelemetry(val);
+    });
     await chars.telemetry.startNotifications();
-    console.log('[TELEM] subscribed, reading initial value');
-    // Initial read so values show immediately. Also force updateChargeUI() here
-    // because parseTelemetry() only calls it on a *change*, and currentChargeStatus
-    // starts at 0 (discharging) - so a discharging device would never trigger the
-    // update and ciStatus would stay at '--'.
     parseTelemetry(await chars.telemetry.readValue());
     updateChargeUI();
 
@@ -447,16 +444,16 @@ function parseTelemetry(dv) {
   const tEl = document.getElementById('telTemp');
   tEl.className = 'telem-val '+(temp>40?'warn':'accent');
 
-  // chargeStatus is now delivered via telemetry (no separate characteristic)
   if (chargeStatus !== currentChargeStatus) {
     currentChargeStatus = chargeStatus;
-    console.log('[TELEM] charge status:', ['discharging','charging','full'][chargeStatus] ?? chargeStatus);
     updateChargeUI();
   }
 
   if (battVoltage !== null) {
     currentBattVoltage = battVoltage;
     document.getElementById('ciVolt').textContent = battVoltage.toFixed(2) + 'V';
+    const pct = Math.round(Math.min(100, Math.max(0, (battVoltage - 3.00) / (4.20 - 3.00) * 100)));
+    if (pct !== currentBattPct) { currentBattPct = pct; updateBatteryBar(pct, currentChargeStatus); }
   }
 }
 function formatUptime(s) {