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Replace cassette screw-and-splice joints with keyed panels and sliding mounts - #13222

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briansrls wants to merge 7 commits into
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session/cassette-joinery-review
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briansrls wants to merge 7 commits into
mainfrom
session/cassette-joinery-review

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@briansrls

@briansrls briansrls commented Oct 4, 2026 •

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Superseded: Consolidated into #13295, which now targets main and includes this branch’s complete joinery ancestry.

The screw-and-splice cassette required 49 printed pieces and 56 fastener axes. Revision 06 replaces it with four keyed tray panels with integral rails/handles, slide-in rear support arms, interlocking rear fan frames, guards with integral spacers/locating pins, and broad-grip retaining pins. The assembly has 17 printed pieces (12 unique geometries), four tray clamps, six fan/guard bolts and five unthreaded retainers. Motherboard standoffs remain a separate unresolved interface; assembly time is not yet measured.

Geometry, placements, typed hardware interfaces, assembly order and prior-fit evidence live in .dag. Review solids use the existing CadQuery exact-dimension realization module, with a distinct review-program carrier and source-manifest binding. The hosted workbench displays those generated meshes and supports individual rotation, explosion, withdrawal, parts lists and review downloads.

Validation: all five new DAG witnesses pass (source bed/mate/member checks, displaced guard, missing member, oversized piece and program/manifest binding). CadQuery 2.8.0 realized all 17 pieces as single valid solids; STL closure/volume/bounds, STEP round-trip, bed fit and printed-pair collision checks passed. Local browser interaction/download/mobile checks pass. The final emitted program and manifest exactly match the executed artifacts. Assembly witnesses are enrolled in the required floor; CI remains pending.

Draft, review-only. Kernel-observation judgments still need migration out of the packaging adapter and execution in CI. Loaded joints, retaining-pin vibration behavior, support/orientation strategy, board standoffs and power/thermal interfaces remain unqualified. This does not grant fabrication admission or start any print. Existing fit evidence is retained; no more gauge sequence is planned.

Separated from printer/auth #13149 and approval-client #13218. Printer operations and slicer implementation changes are excluded.

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