Two-Piece Electronics Enclosure

Design a two-piece electronics enclosure for a desk-mounted Ambient Space Notification System (ASNS). The overall external dimensions must be 115 mm (width) × 110 mm (height) × 55 mm (depth). Use rounded corners with approximately 8 mm corner radius and 3 mm wall thickness. The enclosure should have a removable rear cover secured using four M2.5 screw bosses, one near each corner, with matching screw holes in the rear cover. The front body should remain structurally rigid while the rear cover provides full access to the electronics. On the front panel, create a centered display opening sized to fit a 3.5-inch SPI display with a visible area of 73.4 mm × 48.9 mm. Behind the opening, add four cylindrical display mounting posts (6 mm diameter) with M2 clearance holes positioned to match the display PCB mounting holes for a PCB measuring 98 mm × 56.34 mm. Leave enough clearance so the display sits flush behind the opening without mechanical stress. Below the display, reserve an area for five hidden TTP223 capacitive touch sensors mounted behind the front panel without any button openings. Add five internal mounting ledges or small standoffs positioned approximately 1–2 mm behind the front panel for the 15 mm × 11 mm touch sensor modules, equally spaced in a horizontal row, allowing engraved icons to be placed on the exterior above each sensor. Inside the enclosure, add four mounting standoffs for an ESP32-WROVER-IE development board measuring 54.4 mm × 27.9 mm, leaving at least 5 mm clearance around the board for wiring. Include a mounting platform for a Mini-360 buck converter measuring 17 mm × 11 mm × 4 mm, a small mounting platform for an SN74AHCT125N level shifter measuring 19.3 mm × 6.3 mm × 3.9 mm, and a vertical retaining holder or cable-tie slot for an electrolytic capacitor measuring 18 mm diameter and 25.5 mm height. Include cable-routing channels and tie-down points to keep wiring organized and separated between power and signal wires. Add ventilation slots on the rear panel above the electronics using four horizontal slots approximately 20 mm long and 3 mm wide with equal spacing. On the rear panel, include a centered circular opening of 8.2 mm diameter for a 5.5 mm × 2.5 mm DC barrel jack, positioned 15 mm above the bottom edge. Maintain adequate internal clearance around the connector for wiring. Leave sufficient free space between components for airflow and future maintenance. Optimize the internal layout for manufacturability, structural strength, and easy assembly while preserving the external appearance. The enclosure is intended for PETG printing with 0.2 mm layer height, approximately 30% gyroid infill, and should be robust enough for repeated opening and closing during development.

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