Precision Hinged Aluminium Case

Create a precision hinged aluminium case with the following exact specifications: OVERALL BODY • Exterior width: 300mm • Exterior depth: 220mm • Total height when closed: 22mm • Wall thickness: 2.5mm on all sides • Corner radius: 10mm on all four vertical corners, full height • Material: Aluminium 6061 LID • The case is split into two halves — a base tray and a lid • Split line: 11mm from the bottom — the base tray is 11mm tall, the lid is 11mm tall • Lid thickness: 2.5mm walls, same corner radius as base • Lid exterior top surface: completely flat and smooth • Recessed panel on lid exterior top surface: 290mm wide × 210mm deep, recessed 1.5mm into the lid surface, with a 5mm flat aluminium border remaining on all four sides between the recess edge and the outer corner radius • The recessed panel surface must be completely flat HINGE • Full length piano hinge along the entire rear long edge (300mm side) • Hinge sits flush with the exterior profile — does not protrude beyond the body • Hinge knuckle diameter: 4mm • Hinge leaf width: 8mm each side • The lid opens to 105 degrees and holds position CLOSURE • Front long edge (300mm side, opposite to hinge): magnetic closure • Two neodymium magnet pockets recessed into the mating surfaces of lid and base, centered on the front edge, 60mm apart from center • Each magnet pocket: 10mm diameter, 3mm deep • No visible external hardware on front edge FINGER NOTCH • Centered on the front long edge (300mm side) of the base rim • Position: center of the 300mm front edge • Width: 30mm • Depth: 4mm • Radius at bottom of notch: 2mm • The notch is machined into the top face of the base front rim, allowing a finger to press the lid up INTERIOR TRAY • Interior width: 288mm (300mm minus 2 × 6mm for walls — note walls appear thicker at base due to tray feature) • Interior depth: 208mm • Interior height: 18mm usable depth from base floor to split line • Interior base floor: flat, smooth • Interior tray chamfer: 0.4mm × 45 degrees machined around the full interior perimeter where the floor meets the walls — all four sides and all four corners • Finger relief: 22mm radius curved recess machined into the front interior wall, centered, 25mm wide — this allows a finger to reach under the card stack CARD NOTCH ON TRAY • Small relief notch in the top right corner of the interior tray rim • Dimensions: 15mm wide × 8mm deep × radius 4mm • This allows individual cards to be lifted from the deck LID GAP • When closed: consistent 0.3mm gap between lid and base on all four sides EXTERIOR FINISH NOTE • All exterior surfaces: brushed horizontal grain — grain runs parallel to the 300mm length • All edges: 0.4mm chamfer except the main corner radii

Parameters

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