A support holds a component in a useful position; an enclosure may also protect or group it. Its silhouette alone does not describe its function. Identify user, setting, sensor orientation, USB access, buttons, ventilation, cables and maintenance. A part holding a board securely while covering its sensor fails its purpose even if the drawing looks attractive.

A requirement connects a need with a check: connector access, insertion without force, stability or intended removal. Separate object measurements from design decisions. Width and connector location are observed on the module; wall, base and joining method are chosen according to function and process. A dimensioned sketch locates references, openings and cable travel without assuming that enlarging the whole box solves every problem. Keep the component disconnected during measurement and initial fit tests. A small, removable solution facilitates correction, maintenance and reuse of resources from the previous project.

Designing a cavity requires distinguishing the component’s measured size from the space we choose to leave around it. The nominal dimension is specified in the design; the manufactured dimension may differ because of process, material, geometry and measurement. Tolerance expresses the permitted variation in a dimension. Clearance, by contrast, is the intended space between parts to allow assembly or movement. This distinction explains why a part can be manufactured as intended yet still lack the space needed to fit.

In a centred cavity, clearance per side occurs on both sides of the module. The nominal opening is therefore calculated by adding that clearance twice to the observed width. Walls are then added towards the outside: subtracting them from the opening would reduce the useful space just defined. This relationship connects the object’s measurement with design decisions. The chosen clearance needs checking with the material and profile used; a value working in one print does not guarantee the same fit in another.

Checking starts with an interpretable measurement. A calliper’s resolution makes small changes in its reading distinguishable but does not guarantee accuracy. Contact, orientation and the chosen reference affect the result; repeating critical dimensions and recording units consistent with the instrument supports review. If rubbing occurs, compare the device measurement, nominal opening and manufactured opening in the affected area. Retaining the observed measurement allows the cause to be investigated; changing it to match the drawing would hide the discrepancy.

A parametric model describes dimensions through named values and relationships between them. The module’s observed width is a measurement; clearance and wall thickness are design decisions. If the opening depends on width + 2 × clearance and the exterior on opening + 2 × wall, changing clearance updates the related dimensions while retaining the chosen thickness. A parameter is useful because of that dependency: repeating the same number in several places does not establish a relationship between them.

OpenSCAD turns these dimensions into geometry through operations on solids. cube creates a volume and union combines solids; difference subtracts subsequent solids from the first. To create an opening, the subtracting solid must overlap the part. translate positions it through displacements along x, y and z without changing its size. Moving an opening and widening it therefore produce different effects. The order of operations and the positions of solids determine which material remains in the model.

These relationships also explain a revision. If the opening grows while the exterior remains a fixed number, the wall may become thinner unintentionally. Examining dependencies explains the change before manufacturing. The .scad file retains parameters and decisions for revision; a surface export does not replace it. The guided support provides a starting point for study, while openings, fasteners and dimensions must match the actual module. A parametric model facilitates adaptation but does not guarantee compatibility with every ESP32 without checking.

Exporting a mesh prepares surface geometry for manufacturing. STL preserves neither the source file’s parameters nor an explicit unit that all tools interpret identically. After importing into Bambu Studio, check a known dimension in millimetres. A wrong scale can produce a geometrically similar part that is useless for assembly even when opening the file raises no error.

The slicer converts the model into layers and toolpaths for a particular machine, nozzle, material and profile. An open surface, zero-thickness wall or overly fine feature can produce incomplete paths. Layer preview checks base, walls and openings rather than just exterior appearance. Profile capability constrains manufacturable details; we do not impose a universal thickness without knowing it. The teacher validates P1S and material configuration. Retain source, export and slicing project or profile as different documents: they support revising design, exchanged geometry and process preparation respectively.

A prototype answers specific questions at lower cost than manufacturing the complete assembly. Cardboard checks approximate volume, access and cable location; it reproduces neither printed-material tolerances nor properties. A small test piece can reproduce the fitting area with the chosen profile. Before repeating a whole enclosure, decide which uncertainty to reduce and which test provides that evidence.

Orientation changes supports, overhangs, finish and layer direction relative to loading. Printing supports help manufacture some areas but consume material and require removal. Compare two orientations while keeping model, machine, material and profile constant so estimates are interpretable. Slicer mass and time are predictions, not measured consumption or duration. A lower estimate may fail stability or functional strength. P1S Combo does not require multiple colours or materials; this small part prioritises one material unless a need is justified. The teacher manages printing, removal and machine conditions.

Integrating the support relates it to structure, sensor, control and actuation. It must stabilise the component without covering its sensitive area or obstructing mechanism travel. Resting, snap-fit and screw joints have different conditions: access, rigidity, space, removal and material behaviour. Choosing one requires explaining allowed and constrained movement rather than merely showing a finished box.

Test insertion, removal, connector access and stability with the device disconnected. After assembly review, a supervised functional test shows whether the module still performs its task. If contact occurs locally, measure there and propose a local change. Preserve object measurement, nominal and actual opening, version and before-and-after results. A cardboard model can demonstrate spatial integration but not PLA fit or strength. If printing remains pending, state that status and provide available physical validation without replacing it with a promise or presenting simulation as manufacturing.

The web sheet explains how to use and review the part. HTML organises headings, paragraphs, lists, links and images; CSS changes presentation and readability. An assembly section can have an id linked from an index. Steps should identify module, version, orientation, parameters and checks. An original image is useful when it shows the relevant detail; its alternative text explains that detail rather than merely saying “photo”.

Relative paths link resources inside the project folder, whereas an address from a personal folder can fail when shared. Preserve folder structure and test links to the editable model and corresponding export. The advertised file must match the stated dimensions and version. Authorship, licence and permission differ: citing someone else’s model does not automatically authorise modification or distribution. Identify what you created and what you adapted under compatible conditions. A clear sheet supports reproduction but does not replace mechanical tests; content, navigation and physical operation require complementary checks.

The product combines a part or available physical validation with files enabling process reproduction. Dimension tests check measurements and units; fit tests check insertion, removal and connection; slicing tests compare orientations with a constant profile. These are different kinds of evidence, and no photograph automatically combines them. State whether the record observes cardboard, a test piece, a print or functional assembly and what each supports.

The web test relocates the folder and checks index, images, downloads and links in a narrow window. Moving it reveals personal paths and hidden dependencies. Also check that the downloaded file matches the described support. An improvement may reduce material, solve access or ease maintenance; compare before and after while preserving function and without attributing total environmental impact to one gram figure. While the teacher organises printing and removal, the team continues documentation and tests. Each partner explains a dimension, mechanical decision and correction within the same two submissions.