V4 cuff enclosure and hand-IMU housing

The current CAD uses the actual 100 × 80 × 1.6 mm cuff placement and the routed 16 × 16 × 0.8 mm hand tile. The rigid cuff body is 112 × 104 × 45.5 mm. The flat TPU/textile carrier extends 1.6 mm below the body, giving 47.1 mm total CAD height before textile. The flat overlap window adds1.6mm at the front, so the complete rigid optical assembly is112×105.6×45.5mm. The previous curved mount gave 53.5 mm. This is a large cuff; compact-size-options.md explains the 50.8 × 38.1 mm target and the measured size limits.

clearance-report.json records the current geometry result and physical release checks. independent-stl-audit.json reloads the emitted STL files and independently checks closed surfaces, connected parts, contact attachment, component collisions and every manufactured pair. print-manifest.json distinguishes manufactured parts from inspection envelopes. Camera, battery, PCB and NTC envelopes are reference models. The polycarbonate camera window is a manufactured part.

The current volume-based cuff mechanical budget is approximately 74.18 g: PA12 density 1.01 g/cm³, TPU allowance 1.20 g/cm³, optical PC 1.20 g/cm³ and foam allowance 0.30 g/cm³. Exact per-part volumes and densities are in the report. Adding the 100 g battery, approximately 24 g PCB and 20–35 g electronics/fastener allowance gives approximately 218–233 g before external textile and harness. This calculation uses solid geometry; a slicer infill multiplier is not applied.

Geometry and interfaces

• Main PCB bottom Z29.0, top Z30.6. Four edge ledges touch the underside. The lid captures four 0.8 mm foam pads in a nominal 0.5 mm gap; the modeled 0.3 mm compression is bounded explicitly. Existing board edges carry the clamp loads.
• PA12 shell walls, floor and lid panel 1.3 mm. Local thicker collars support glands, the gasket, fasteners and button. Hollow screw columns have 2.8 mm powder-cleanout ports. The flat 1.6 mm TPU carrier includes strap loops and four captured mushroom posts through the floor.
• Five front finger glands, one right hand-IMU gland and one left palm gland have stepped retention seats. Cast the glands intact, then knife-cut from bore to insertion edge with zero material removal; the assembled CAD represents closed slit faces. Seven internal blanking plugs close unused bores. USB and SD have removable service caps. Cable bundle sleeves are formed to 4.0 mm OD for the 3.8 mm nominal gland bores; inspect actual compression after harness build.
• A continuous 0.8 mm closed-cell silicone gasket occupies a 0.6 mm lid seat. The exact 0.2 mm compression region is audited. The component collision audit contains no blanket grommet/base exclusions. Rear lid screws at (24,86) and (36,86) clear the mated battery plug, wire return and SD service area. Polymer ribs stiffen the left/rear panel; the longest adjacent screw chord is113.2mm. A supplier-approved flatness/compression fixture must establish the full perimeter0.60±0.05mm gap; the nominal model does not prove seal-load uniformity.
• J14 is at (90, 23.95), facing −Y; J15 is at (81, 14). These changes prevent the camera from intersecting the main board or the hand-IMU connector.
• The camera is Camthink 73.002.000035: 8.5 × 8.5 mm face, 6.6 ± 0.2 mm optical depth. Its lens faces −Y. The 38.5 mm flat length is exactly 8.5 mm head + 26 mm neck + 4 mm tail. A 19.7168147 mm straight neck and R4 quarter bend use exactly 26 mm. The tail has its contacts toward −Z in the bottom-contact FH12. The rear carrier includes an R3.9 inner bend guide, cradle liner and four front corner shims; two screws retain the rear plate. Revised Ø7.6 mm lugs, 5.3 mm nut insertion slots and straight driver channels provide actual assembly access.
• FH12 drawing EDC3-150229-11 supplies the 0.55 mm contact-bottom reference and 4.4 mm insertion reference. The 0.3 mm tail center is Z31.3. These reference dimensions establish the nominal CAD; incoming camera/connector measurements are used for the carrier shims before window bonding.
• A conservative circular 120° cone starts at the complete 5.96 mm lens face. It clears the opaque parts. The flat-window tolerance stack includes camera depth, printed/finished land, adhesive, sheet, die-cut and registration limits. Remaining minimum radial margins are0.487mm at the tape opening,1.082mm at the PCedge and0.184mm in the optical tunnel. Incoming camera/flex inspection and fitting of the carrier shims remain assembly acceptance steps.
• The RGB light pipe begins above the real 1.6 × 1.6 × 0.9 mm maximum LED and bends to the lid face at (60, 76), away from the button diaphragm.
• The hand-tile housing has a removable retained cover, four sewing holes, split cable exit and a raised arrow. Align the arrow distally along the third metacarpal, stitch the flanges to the textile, and secure a cable strain-relief loop toward the wrist. The +140 mm X translation in the CAD is a drawing layout offset. Its seven real component envelopes are separately checked.

Button, materials and fabrication

The C&K PTS636 SK43 SMTR LFS actuator is 4.3 ± 0.2 mm high with 0.30 ± 0.10 mm travel. The button has a captured floating tip, an internally preloaded spring, a 0.8 mm rigid stop, a separately assembled cap and a bonded diaphragm. Its released gap is set to 0.05–0.25 mm against the measured mounted switch.

The selected spring is SDP/SI S78CSYM030035008, catalog Type302 stainless, 3mm OD,8mm free length,2.8mm solid length and1.26N/mm nominal rate, squared and ground ends. button-spring-specification.md specifies receiving force/rate checks and the factory gap/stop settings. First article overload/cycle testing uses the4.69N worst accepted contact force.

Quote the rigid shell, lid and camera retainer in natural-gray JLC PA12-HP MJF. Their broad faces are 1.3 mm; local camera lug/guide details require the supplier to accept the process-specific geometry. The button has 1.0 mm retaining ledges and 0.8 mm diametral sliding clearances. Its small-part print/sprue and finishing route needs acceptance; machined PA12 is an alternative requiring a quote. Set the nose against the actual mounted switch and finish the guide pin to ≤2.05 mm. The light pipe is machined/bent optical polycarbonate. The camera window is a Ø22±0.2mm disk cut from RS PRO7698720 stock1mm PCsheet, bonded on a flatØ24mm land using a die-cut3M VHB LSE-060WF ring,OD22/ID17mm. See window-fabrication.md for PA12 surface preparation, Primer94, land flatness, pressure, registration and cure requirements. The flat carrier is a TPU95A FDM quote candidate. Glands, plugs, service caps, battery belt and tile housing require a separately accepted cast/precision elastomer route; JLC's published TPU minimum size and wall limits exclude these small thin parts as ordinary individual FDM orders. Thin camera shims, PCB pads, battery pads and the perimeter gasket are cut parts rather than ordinary FDM prints. The camera cradle liner is heat-formed 0.20 mm TPU film with a 0.25 mm rear patch; its STL shows the assembled liner.

The button diaphragm is platinum-cured VMQ silicone, 40 ± 5 Shore A, 0.60 ± 0.05 mm thickness, cut to the emitted rounded outline. Minimum elongation 300%, tensile strength 7 MPa and tear strength 20 kN/m are manufacturer acceptance requirements. Its outer 2 mm flange bonds into the lid rebate; the central region bonds to the moving cap, leaving approximately 3 mm free span around the cap.

Use Permabond2050 for the diaphragm and plunger-cap joint. Apply Permabond POP only to silicone surfaces; dry/abrade/clean PA12. The optical window uses its separately specified acrylic foam tape process.

Assembly order

1. Inspect print coupons, plunger fit, hole diameters and gasket seats. Finish the nut slots and powder-cleanout ports. Verify each exported part is present.
2. Bond and cure the window and light pipe. Insert camera lug nuts from below, fit the liner, shims and camera head, then fit the rear retainer using two M2 × 6 low-head screws. Use the verified straight Ø3 mm driver paths while the battery and main PCB are still outside the base.
3. Fit the flat carrier posts and 1.7 mm battery foam pads. Wrap the nominal 69 × 38 × 20 mm pack in insulating foam shims to the 72 × 39 × 21 mm assembly envelope. Slide the retaining belt over the padded assembly, seat it and tape the insulated NTC to its upper-face pocket, clear of the belt.
4. Seat the main PCB on its edge ledges. Insert the FPC fully and close the FH12 latch. Dress the direct Micro-Fit battery leads and PH NTC leads and the mated GH/SH harnesses. Fit the split glands around sleeved bundles; use the blanking plugs for unused ports.
5. Insert the button tip and selected catalog spring through the plunger's open top; bond the separate cap with its spring guide pin. Set the nose length against the actual switch, verify released continuity and operation before the hard stop, then bond the diaphragm to the cap and lid rebate.
6. Fit four M2 ISO4032 nuts into the base bosses, the PCB clamp pads and perimeter gasket. Close with four M2 × 8 ISO14580 low-head screws. Target even gasket compression; use a torque coupon to qualify the selected PA12 process.
7. Insert the hand tile, connect its harness, close its TPU cover and stitch the sewing flanges to the glove. Thread 24 mm webbing through the flat carrier loops.

Verification and manufacturing release

PYTHONPATH=/tmp/glove-engineering/caddeps python3 hardware/glove-v4/enclosure/generate_enclosure.py
PYTHONPATH=/tmp/glove-engineering/caddeps:/tmp/glove-engineering/auditdeps python3 hardware/glove-v4/enclosure/verify_enclosure.py

The independent audit covers the actual 48 STL files, 861 manufactured pairs and 23,562 main-component/part comparisons. The generator additionally checks 17 cap positions, 324 fitted-tip tolerance poses including0.85mm maximum accepted cap stroke, the camera/PCB/FPC interfaces, 120° cone, metal/RF exclusion and fastener fit. The module's own antenna is the only RF-envelope exemption. The export component-envelopes.json contains the exact audited solids used by the viewer.

The process state is first_article_fabrication_ready: false. Obtain the listed print-and-finish, small elastomer, optical-part and button process quotes; qualify the selected wire OD/static bend radius; and establish the measured seal and PCB-pad compression plan. These are explicit process items, separate from physical testing after a first article exists. Critical finished fits include window landflatness≤0.20mm, disk/ring registration≤0.30mm, gasket gap0.60±0.05mm, button released gap0.05–0.25mm and cap stroke0.80±0.05mm. Nominal MJF tolerance requires local measurement and finishing for these assembly fits.

The independent audit also checks actual harness service volumes, nut insertion paths and Ø3 mm camera/lid screwdriver access. A wired port replaces only its own blanking plug. PH/GH routing reservesR2.5mm; supplier wire bend acceptance and full harness lead dressing remain process work. The battery connector uses direct AWG22-compatible Micro-Fit contacts, with the selected header placed within the manufacturer's edge-distance limit. The direct variant uses the original pack leads; a separately identified factory extension variant adds35mm AWG22 per lead with5mm overlap, giving30mm effective reach gain per lead. Its exactR4 paths pass through two staggeredØ4×16mm insulated-joint envelopes. Worst external route74.174mm leaves3.576mm margin after conservative connector consumption and3mm slack with the shortest65mm stock leads. Seebattery-connector-fit.md.

Physical acceptance remains subject to: supplied component-height and camera-tail inspection; first-article PCB pad compression; switch force/return/cycle tests; cable pull and strap-retention tests; window/diaphragm/gland dust-and-splash tests; panel/drop and temperature testing; and finished-system mass/fit measurement. All545 former generic package heights are now documented manufacturer maxima plus a separate0.20mm assembly allowance. height-evidence/README.md links the94 selected-MPN records, primary source locations and evidence hashes. The new fuse uses2.94mm manufacturer maximum plus0.20mm assembly allowance.

Primary evidence

• Camthink camera specification and outline, captured in ../interfaces/sources/ov5640-outline-browser.png.
• Hirose drawing ../interfaces/sources/fh12-family-engineering-drawing.pdf, page 1 detail a; family catalog alongside it.
• C&K PTS636 drawing ../../glove-v3/component-evidence/interfaces/pts636-datasheet.pdf.
• Kingbright ../interfaces/sources/kingbright-aptf1616-rgb.pdf.
• HP PA12 manufacturer datasheet, part density 1.01 g/cm³.
• Permabond silicone preparation and 2050 technical datasheet.

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