AEGISX Enclosure

Create a parametric 3D printable enclosure for a Raspberry Pi 5 based AI cybersecurity appliance named AEGISX. Overall dimensions: - Width: 255 mm - Height: 170 mm - Depth: 95 mm - Wall thickness: 3 mm - Corner radius: 8 mm - Material: PETG The enclosure consists of two interlocking L-shaped parts. Part 1 (Main Chassis): - Includes front, bottom, rear and left side. - Houses the Raspberry Pi 5, 7-inch touchscreen, rechargeable battery, fan mounts and internal supports. - Contains mounting bosses and cable routing. - Display remains permanently attached to this chassis. Part 2 (Cover): - Includes top and right side. - Slides over the main chassis. - Secured with M3 screws into brass heat-set inserts. - Removing the cover provides full internal access without removing the display. Front Panel: - Centered opening for Official Raspberry Pi 7-inch Touch Display. - Display opening approximately 186 × 118 mm with 2 mm bezel overlap. - Display module size: 189 × 121 mm. - Display sits flush with the front surface. - Below display: - One illuminated 19 mm power button. - One 5 mm green power LED. - Leave space for embossed "AEGISX" logo. Rear Panel: Create aligned cut-outs for: - 2 USB-A ports - 1 RJ45 Ethernet port - 1 USB-C charging port - 1 rotary volume wheel opening (8 mm diameter) - 2 SMA WiFi antenna holes (6.5 mm diameter, 20 mm spacing) Maintain at least 10 mm spacing between all ports. Left Side: - One 40 mm intake fan. - Standard 32 mm fan screw spacing. - Honeycomb ventilation surrounding the fan. Right Side: - One 40 mm exhaust fan. - Standard 32 mm fan screw spacing. - Honeycomb ventilation matching left side. Internal Mounts: Create mounting bosses for Raspberry Pi 5: - Board size: 85 × 56 mm - Four M2.5 mounting holes - 7 mm standoffs - Rear ports aligned with rear cut-outs. Touchscreen: - Four mounting bosses. - Internal cable clearance. - Ribbon cable routing channel. Battery: - Compartment size: 150 × 75 × 22 mm. - Removable battery bracket. - Space for charging/BMS board. Cable Management: - Integrated cable channels. - Zip tie anchors. - Separate routing for display, battery and fan cables. Cooling: Two 40 mm fans. Airflow: Left intake → Battery → Raspberry Pi → Expansion space → Right exhaust. Fasteners: - M3 screw holes. - Brass heat-set insert pockets. - Countersunk screw heads where appropriate. Printing: - Optimized for FDM PETG. - Split into printable parts. - Minimal support material. - Flat surfaces suitable for 256 × 256 mm print bed. Style: Modern enterprise cybersecurity appliance. Smooth rounded edges. Professional matte finish. Flush touchscreen. Hidden screws. Symmetrical design. Honeycomb side vents. Commercial appearance similar to Ubiquiti or Fortinet network appliances.

Parameters

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