Overall System Requirements

Mechanical

1. All major subcomponents (Main Instrument Panel (MIP), Left Console, Right Console, etc.) shall be capable of movement through a standard 30-inch-wide interior residential door.
2. All major subcomponents shall be able to be assembled and disassembled from each other with minimal hand tools for transit purposes.
3. System will be designed to occupy a minimal overall footprint, with the exception of major accessories, including, but not limited to, PC or LCD/TFT/TV/projector visual outputs.
4. Minimum tooling required shall consist of:
   1. a hobby-grade 3D FDM printer (Prusa i3 MK3 or equivalent.)
   2. a hobby-grade resin 3D printer (Anycubic Photon Mono or equivalent.)
   3. a hobby-grade CNC Router (XCarve 1000x1000 or equivalent.)
   4. a hobby-grade CO2 laser (K40 or similar)
   5. common hand/power tools (Drill, screwdrivers, sanders, wrenches, ratchets and sockets, calipers, tape measure, ruler, square, marking devices, etc.)
   6. basic electronics assembly equipment (multimeter, soldering station, magnifier (optional), desolder vacuum, desolder braid, solder, flux.)
5. All components shall be designed with a major consideration for ease of future maintenance.
6. Hardware Components such as nuts/bolts/springs/washers/etc shall be sourced from McMaster-Carr.

Electrical

1. Input electrical requirement: 120AC @ 60hz.
2. Overall system shall run on +12V, +3.3V, and +5V buses (with the exception of major accessories, including, but not limited to, PC or LCD/TFT/TV/projector visual outputs.)
3. All PCB deliverables shall be submitted using KiCAD format, following the same format as other PCBs in the repository and all custom footprints/symbols added to the applicable OH library with applicable 3D models.
4. PTH Components shall be sourced from Digikey or Mouser. If it is not available from one of the two, contact a developer to verify that the suggested source of supply is acceptable. (AliExpress is a supplier of absolute last resort.)
5. SMD Components shall be sourced from JLCPCB for JLCPCB assembly.

Panel Requirements

Panel Stackup

Panels shall consist of the following plys:

1. 0.125 (1/8) inch clear acrylic (Backplate)
2. 0.1875 (3/16) inch clear acrylic light plate (Light Plate)
3. 0.0625 (1/16) inch Rowmark Ultra-Matte, White on Black (Legend Plate) (Equivalent 2-ply rotary engravable materials may be substituted as desired.)

Panel Construction

• Light Plate and Legend Plate shall be bonded with Weld-On #4 or equivalent, then painted IAW FED-STD-595, 37038, Lusterless Black, prior to engraving.
• Backplate shall be painted IAW FED-STD-595, 37038, Lusterless Black.
• Bonded Light and Legend Plate assembly shall be assembled to the Back Plate with #6 screws, unless otherwise required for specific application.
• Backplates shall be installed to consoles with #8 flathead screws with printed DZUS head replicas.

Panel Typography

• Legend Panels shall be engraved to the minimum depth as specified by the material manufacturer.
• All fonts shall be Gordon Medium Bold or Gordon Medium Condensed Bold as required for specific application.
• 14-point sized font shall be standard, increasing and decreasing as required for specific application.
• On panel revision, the following font sizes shall be adhered unless deviation is required for specific purpose:
  • Panel Label (ECS, SNSR, etc.): 21pt
  • Main Label (MODE, TEMP, etc.): 17pt
  • Position Label (ON, OFF, AUTO, etc.): 14.5pt

Structural Requirements

• Major structural components shall be fabricated from .75, .50, and .25 MDF or birch ply as required.
• Any component designed to bear the weight of a human shall be able support a 250 lb static load.