OpenAPS system tray with cover, LiPo/ERF

thingiverse

I switched to an ERF radio shortly after designing my last OpenAPS case (http://www.thingiverse.com/thing:1525618), so I decided to try again. Design goals this time around: Smaller Lighter Access to console port Access to power button Easier to open Easier to build Easier to print This new case is 52mm x 21mm x 65mm and 92g fully assembled, which may not sound like much of an improvement, but which yields a device that feels significantly smaller and less bulky. Because LiPo batteries can catch fire if punctured, the case has been specifically designed to provide a secure battery slot to prevent damage (USE AT YOUR OWN RISK). In addition to the Intel Edison compute module and mini breakout board kit, it also accommodates an ERF radio (discontinued, but sometimes available here), an Adafruit MicroLipo charger (with 500mAh charging current enabled), and a 2,500mAh LiPo battery also from Adafruit. A few notes on assembly: I have been using Schmartboard jumper cables to make secure connections between the ERF and Edison. While they are more expensive than other jumper cables, they fit much tighter and are a lot less bulky. You will also need right angle header pins (cheaper ones should work fine here). I have clipped all of the Edison's power pins except J2, which I have bent to 90 degrees to provide more clearance for the case cover, The blue wire attached to the ERF is an optional wire whip antenna that I added while testing RF coverage. It is an 868 1/4 wave antenna made from a piece of 22AWG solid core wire trimmed to 82.2mm. If you add an antenna, try not to make sharp bends when arranging it around the other components). More info here, but again, this part is completely optional. I've included a couple of closeup photos to help with wiring and assembly. For additional information, see OpenAPS documentation and Gitter channel as well as the MMEowlink wiki and Gitter channel. I will respond to comments left here as I see them, but the best way to reach me is on Gitter. Tinkercad source files available here: https://tinkercad.com/things/5TxAPLeh0cGhttps://tinkercad.com/things/6mhhH5CaXh7https://tinkercad.com/things/cYRPTij6L1U