# /mechanical/stl

3D printable files for all mechanical components and sub-assemblies.

## Purpose
This directory contains STL files ready for 3D printing, organized by functional categories. These files support prototyping, custom tooling, replacement parts, and production components.

## Organization by Function
Organize STL files by their intended use and sub-assembly:

```
stl/
├── enclosure-parts/            # 3D printable enclosure components
│   ├── housing-prototypes/
│   ├── custom-panels/
│   ├── mounting-brackets/
│   └── access-covers/
├── mounting-hardware/          # Custom brackets and mounting solutions
│   ├── pcb-mounts/
│   ├── sensor-brackets/
│   ├── cable-management/
│   └── standoffs-spacers/
├── prototyping/                # Prototype and development parts
│   ├── concept-models/
│   ├── fit-test-parts/
│   ├── functional-prototypes/
│   └── design-iterations/
├── tooling/                    # Assembly and manufacturing aids
│   ├── assembly-jigs/
│   ├── test-fixtures/
│   ├── alignment-tools/
│   └── handling-fixtures/
├── replacement-parts/          # Service and maintenance components
│   ├── wear-parts/
│   ├── consumables/
│   └── field-replaceable/
└── custom-components/          # Project-specific mechanical parts
    ├── actuator-parts/
    ├── interface-components/
    ├── structural-elements/
    └── specialty-hardware/
```

## File Naming Convention
Following [FILE-NAMING-AND-VERSIONING.md](../../FILE-NAMING-AND-VERSIONING.md) standards:
- `project-name_pcb-mount-bracket_v2.1.0_petg.stl`
- `project-name_sensor-housing-top_v1.0.0_abs.stl`
- `project-name_cable-gland_v1.2.0_tpu.stl`
- `project-name_assembly-jig_v1.0.0_pla.stl`

### Naming Structure
`[project-name]_[component-description]_[version]_[material].stl`

### Material Suffixes
- `_pla` - PLA filament
- `_petg` - PETG filament
- `_abs` - ABS filament
- `_tpu` - TPU flexible filament
- `_asa` - ASA filament
- `_pc` - Polycarbonate filament

### Versioning Strategy
- **MAJOR**: Dimensional changes affecting fit/function
- **MINOR**: Feature additions, improvements
- **PATCH**: Print setting optimizations, minor corrections

## Print Settings Documentation
Include recommended print settings for each component:

### Material Recommendations
- **PLA**: Prototyping, non-critical parts, tooling
- **PETG**: Mechanical parts, chemical resistance
- **ABS**: Structural components, higher temperature resistance
- **TPU**: Flexible parts, gaskets, vibration dampening
- **ASA**: Outdoor use, UV resistance
- **PC**: High strength, high temperature applications

### Print Quality Settings
Document recommended settings for each part:
- **Layer Height**: 0.1mm (fine), 0.2mm (standard), 0.3mm (draft)
- **Infill**: 10-20% (light), 40-60% (standard), 80-100% (structural)
- **Support**: Required/not required, support type
- **Orientation**: Optimal print orientation for strength/finish
- **Post-Processing**: Required finishing operations

## Quality Control
### Print Validation
- **Dimensional Accuracy**: Critical dimensions and tolerances
- **Surface Finish**: Required surface quality
- **Mechanical Properties**: Strength and durability requirements
- **Fit and Function**: Assembly and mating requirements

### Testing Procedures
- **Fit Testing**: Verify assembly with mating parts
- **Functional Testing**: Confirm operational requirements
- **Durability Testing**: Lifecycle and wear testing
- **Environmental Testing**: Temperature and chemical resistance

## Manufacturing Notes
### Production Considerations
- **Print Time**: Estimated printing duration
- **Material Usage**: Filament consumption estimates
- **Batch Production**: Multiple part printing strategies
- **Quality Assurance**: Inspection and acceptance criteria

### Alternative Manufacturing
Document when injection molding or machining might be preferred:
- **Volume Thresholds**: When to consider other processes
- **Material Limitations**: Properties not achievable with 3D printing
- **Tolerance Requirements**: Precision beyond 3D printing capabilities
- **Surface Finish**: Requirements for smooth or textured surfaces

## File Management
### Version Control
- Include version numbers in filenames
- Document changes in commit messages
- Tag releases for production parts
- Maintain design history and rationale

### Source File References
- Link STL files to source CAD files
- Document any modifications made for 3D printing
- Include original design intent and specifications
- Reference assembly drawings and instructions

## Print Instructions
### Setup Requirements
- **Printer Specifications**: Minimum build volume and capabilities
- **Material Preparation**: Drying and storage requirements
- **Bed Preparation**: Adhesion and leveling requirements
- **Environmental Conditions**: Temperature and humidity control

### Post-Processing
- **Support Removal**: Techniques and tools required
- **Surface Finishing**: Sanding, smoothing, or coating
- **Assembly Preparation**: Drilling, tapping, or fitting operations
- **Quality Inspection**: Dimensional and visual checks
