Main Enclosure Mechanical Design Specification

Status: Stub — pending detailed mechanical design Project: Enigma-NG Author: Izzyonstage & GitHub Copilot Version: v0.2.0 Associated Hardware Revision: Rev A Last Updated: 2026-04-20

Overview

Mechanical design specification for the main Enigma-NG enclosure. This encompasses the physical housing of the Controller Board, Stator Board, rotor stack, the Keyboard Assembly, the Lightboard Assembly, and the user-accessible Settings Board panel switches.

Content to be populated during detailed mechanical design phase.

Panel Cutout Requirements

Settings Board — Configuration Switch Panel

The right side of the enclosure top face, positioned near the rotor stack, must provide panel cutouts for the 12 Settings Board toggle switches, 12 matching RGB indicator LEDs, and 1 CFG_APPLY pushbutton.

Feature	Quantity	Location	Notes
Toggle switch cutouts (Bank 1 — Plugboard Routing)	5	Right side, top face, near rotors	Bank 1 enable + SW_B1[0:3] — panel-mount SPDT toggle
Toggle switch cutouts (Bank 2 — Reflector Mapping)	7	Right side, top face, near rotors	Bank 2 enable + SW_B2[0:5] — panel-mount SPDT toggle
RGB LED apertures (Bank 1 indicators)	5	Adjacent to Bank 1 toggles	One 5mm indicator LED per switch position
RGB LED apertures (Bank 2 indicators)	7	Adjacent to Bank 2 toggles	One 5mm indicator LED per switch position
CFG_APPLY actuator cutout	1	Right side, top face	Opening for a mechanical actuator/plunger that presses the Settings Board's internal momentary tactile switch; triggers CPLD config re-latch

The Settings Board PCB mounts internally to the enclosure panel, with the toggles and LEDs protruding through their panel cutouts. CFG_APPLY may instead use an internal board-mounted tactile switch with a simple actuator/plunger through the panel opening. The board connects to the Stator Board via a 6-wire JST PH harness (3V3_ENIG, 5V_MAIN, GND, SDA, SCL, GND), with 5V_MAIN feeding the Settings Board RGB indicator rail. Final toggle-hole, LED-hole, and stand-off / spacer geometry are to be defined at detailed mechanical design phase based on the selected parts.

See design/Electronics/Settings_Board/Design_Spec.md for the electrical specification of the Settings Board.

Lid Display — Optional Touchscreen Add-on

The machine lid must be designed to accommodate an optional touchscreen display add-on (see DEC-033). Specific mounting dimensions are deferred pending display size selection (up to 10" supported via DSI1). The following provisions must be made at detailed mechanical design phase:

Feature	Notes
Display aperture in lid	Sized for chosen display (TBD — up to 10"); flush-mount or recessed bezel
Display mounting frame / bracket	Secures display panel against lid inner face
FPC hinge routing	Clear path for DSI1 FPC cable from lid through hinge to Controller Board J_DSI1
Deferred display auxiliaries	No separate display power or touch harness is fixed yet; reserve hinge space beyond the J_DSI1 FPC path only as future margin until the display add-on is defined

See design/Electronics/Controller/Design_Spec.md (J_DSI1) and design/Electronics/Settings_Board/Design_Spec.md for electrical context.

Cross-References

Document	Description
design/Electronics/Controller/Design_Spec.md	Controller Board electrical specification
design/Electronics/Controller/Design_Spec.md	Controller Board — DSI1 connector J_DSI1 for lid display
design/Electronics/Stator/Design_Spec.md	Stator Board electrical specification — includes I²C interface to Settings Board
design/Electronics/Settings_Board/Design_Spec.md	Settings Board electrical specification — panel switch and LED expanders
design/Mechanical/Keyboard_Assembly/Design_Spec.md	Independent keyboard sub-assembly mounted into the enclosure
design/Mechanical/Lightboard_Assembly/Design_Spec.md	Independent lightboard sub-assembly mounted into the enclosure
design/Mechanical/Complete_System_Assembly/Design_Spec.md	Complete system assembly including all sub-assemblies