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Request for mechanical design quotation – panoramic dual-camera enclosure Ended
About the job
My name is Mohamed Jâafar, and I am based in France. I am developing a self-contained, battery-powered panoramic camera for recording, streaming and analyzing football matches.
I already have a functional electronics and software prototype using two synchronized 4K cameras and a Radxa ROCK 5B+. I am looking for assistance converting the handmade prototype into a professional, rigid and manufacturable enclosure.
The main requirements are:
* A rigid dual-camera mounting system that preserves calibration
* Minimum parallax between the two cameras
* Proper cooling for the ROCK 5B+
* Safe retention of the Li-ion battery
* Professional industrial design
* Prototype-ready STEP and STL files
The camera angle and optical geometry have already been established experimentally, so I do not need optical-system development from scratch.
1. Current calibrated camera geometry
The current handmade mount was measured through the deployed Hugin calibration:
* Camera A yaw: +24.97°
* Camera B yaw: −24.50°
* Measured optical-axis separation: 49.47°
* Relative pitch difference: approximately 2.86°
* Camera A: +1.06°
* Camera B: −1.80°
* Camera B residual roll: approximately 0.4°
These pitch and roll differences are manufacturing errors absorbed by calibration. A new professional mount should target equal pitch and zero relative roll rather than intentionally reproducing these errors.
For a new symmetric mount, the nominal camera positions should therefor... read more
I already have a functional electronics and software prototype using two synchronized 4K cameras and a Radxa ROCK 5B+. I am looking for assistance converting the handmade prototype into a professional, rigid and manufacturable enclosure.
The main requirements are:
* A rigid dual-camera mounting system that preserves calibration
* Minimum parallax between the two cameras
* Proper cooling for the ROCK 5B+
* Safe retention of the Li-ion battery
* Professional industrial design
* Prototype-ready STEP and STL files
The camera angle and optical geometry have already been established experimentally, so I do not need optical-system development from scratch.
1. Current calibrated camera geometry
The current handmade mount was measured through the deployed Hugin calibration:
* Camera A yaw: +24.97°
* Camera B yaw: −24.50°
* Measured optical-axis separation: 49.47°
* Relative pitch difference: approximately 2.86°
* Camera A: +1.06°
* Camera B: −1.80°
* Camera B residual roll: approximately 0.4°
These pitch and roll differences are manufacturing errors absorbed by calibration. A new professional mount should target equal pitch and zero relative roll rather than intentionally reproducing these errors.
For a new symmetric mount, the nominal camera positions should therefor... read more
My name is Mohamed Jâafar, and I am based in France. I am developing a self-contained, battery-powered panoramic camera for recording, streaming and analyzing football matches.
I already have a functional electronics and software prototype using two synchronized 4K cameras and a Radxa ROCK 5B+. I am looking for assistance converting the handmade prototype into a professional, rigid and manufacturable enclosure.
The main requirements are:
* A rigid dual-camera mounting system that preserves calibration
* Minimum parallax between the two cameras
* Proper cooling for the ROCK 5B+
* Safe retention of the Li-ion battery
* Professional industrial design
* Prototype-ready STEP and STL files
The camera angle and optical geometry have already been established experimentally, so I do not need optical-system development from scratch.
1. Current calibrated camera geometry
The current handmade mount was measured through the deployed Hugin calibration:
* Camera A yaw: +24.97°
* Camera B yaw: −24.50°
* Measured optical-axis separation: 49.47°
* Relative pitch difference: approximately 2.86°
* Camera A: +1.06°
* Camera B: −1.80°
* Camera B residual roll: approximately 0.4°
These pitch and roll differences are manufacturing errors absorbed by calibration. A new professional mount should target equal pitch and zero relative roll rather than intentionally reproducing these errors.
For a new symmetric mount, the nominal camera positions should therefore be:
* Left camera yaw: +25°
* Right camera yaw: −25°
* Nominal optical-axis separation: 50°
* Equal pitch for both cameras
* Relative roll: 0°
The existing Hugin maps are baked from the current 49.47° geometry. The system will be recalibrated after installation in the new enclosure.
2. Camera field of view and mounting-angle options
Each Radxa Camera 4K uses the stock lens with the following published field of view:
* Horizontal FOV: 75° ±3°
* Vertical FOV: 59° ±2°
* Diagonal FOV: 88.2° ±5°
The relationship between camera separation, overlap and total field of view is approximately:
* 49.5° separation: approximately 25° overlap and 124° total coverage
* 55° separation: approximately 20° overlap and 130° total coverage
* 58–60° separation: approximately 15–17° overlap and 133–135° total coverage
* 65° separation: approximately 10° overlap, placing the seam too close to the soft and vignetted lens edges
* Above 67°: insufficient overlap for reliable stitching
For the current lenses, my preferred robust position is approximately 50°. This keeps the seam approximately 12.5° inside each lens edge, where image sharpness and brightness are better, particularly at night.
A 58–60° position may be useful as a maximum-coverage configuration, but I do not want the current lenses operated beyond approximately 62° separation.
I would like the mechanical design to provide:
* A rigid nominal position at 50° total separation
* Adjustment from approximately 49° to 62°
* Clear engraved or indexed positions at 50°, 55° and 60°
* A positive locking mechanism that cannot move after calibration
* Symmetric adjustment around the enclosure centerline
* Both lens centers at exactly the same vertical height
* Pitch adjustment of approximately ±5° for initial alignment
* Roll alignment as close to 0° as mechanically practical
The product may later use approximately 95° HFOV M12 lenses. With these wider lenses, approximately 62° separation would produce around 157° of total coverage with approximately 33° of overlap. The adjustable mount should therefore support the future 62° configuration.
3. Parallax and camera spacing
Minimizing parallax is more important than achieving sub-degree yaw accuracy.
The two camera lens entrance pupils should be positioned as close together as mechanically possible. The previous concept using approximately 140 mm lens spacing should not be used.
I would like 219 Design to determine the minimum practical lens-center separation using the camera STEP geometry. A preliminary target would be approximately 40–60 mm, subject to PCB, FFC connector, lens barrel and mounting-bracket clearances.
The mount must be very rigid. Any movement after Hugin calibration invalidates the baked stitching maps. The cameras should remain calibrated during transportation, tripod installation and normal outdoor operation.
Each camera should have an individual replaceable protective window positioned perpendicular to its optical axis. The clear aperture should be at least 18–20 mm to prevent vignetting.
4. Camera hardware
The system uses two identical Radxa Camera 4K modules with Sony IMX415 sensors.
Approximate dimensions for each camera:
* PCB: 32 × 32 mm
* PCB thickness: approximately 1.6 mm
* Mounting-hole pattern: 28 × 28 mm
* Complete camera depth: approximately 15.74 mm
* Lens barrel maximum diameter: approximately 14 mm
* Lens mount: M12 × 0.5
* FFC cable length: 150 mm
* MIPI CSI-2, four lanes
Camera documentation:
[https://dl.radxa.com/accessories/camera-4k/radxa_camera_4k_product_brief.pdf](https://dl.radxa.com/accessories/camera-4k/radxa_camera_4k_product_brief.pdf)
The two FFC camera cables require strain relief, controlled routing and no sharp folds. A minimum bend radius of approximately 5 mm should be maintained.
5. Main processor board
The main processor is:
* Radxa ROCK 5B+
* Hardware revision V1.2
* Reference PCB envelope: approximately 100.19 × 74.24 mm
* One M.2 2280 NVMe SSD installed underneath
* Two MIPI-CSI camera connections
The official V1.2 STEP model must be used for exact mounting holes, connector positions and component heights. The older ROCK 5B CAD model is not interchangeable with my ROCK 5B+ V1.2.
Official mechanical resources:
[https://docs.radxa.com/en/rock5/rock5b/download](https://docs.radxa.com/en/rock5/rock5b/download)
Direct V1.2 STEP model:
[https://dl.radxa.com/rock5/5b%2B/docs/hw/rock5bp_pcba_3d_V1_2_20250314.stp](https://dl.radxa.com/rock5/5b%2B/docs/hw/rock5bp_pcba_3d_V1_2_20250314.stp)
6. Cooling
The ROCK 5B+ uses the official Radxa Heatsink 6240B V2.0:
* Dimensions: 62 × 40 × 9 mm
* Integrated 5 V fan
* Fan speed: up to approximately 7,000 RPM
* At least 15 mm of unobstructed air should remain above the fan intake
The enclosure needs a defined cool-air intake and warm-air exhaust path. The battery must not be placed in the ROCK 5B+ hot-air exhaust.
Heatsink documentation:
[https://docs.radxa.com/en/accessories/heatsink-case/heatsink-6240b](https://docs.radxa.com/en/accessories/heatsink-case/heatsink-6240b)
7. Battery
I have purchased an ENERpower 4S2P Li-ion battery:
* Cells: INR21700-M50T
* Configuration: 4S2P
* Nominal voltage: 14.4–14.8 V
* Fully charged voltage: 16.8 V
* Capacity: 10,000 mAh
* Energy: approximately 144–148 Wh
* Dimensions: 85 × 72 × 46 mm
* Weight: approximately 600 g
* Integrated 8 A protection PCB
* Published maximum power: 115 W
* Open-ended charging and discharging cables
* Cable length: approximately 100–150 mm
Battery documentation:
[https://enerprof.de/en/products/enerpower-4s2p-akku-14-4v-14-8v-10000-mah-li-ion-m50t-mit-kabeln-offenen-enden](https://enerprof.de/en/products/enerpower-4s2p-akku-14-4v-14-8v-10000-mah-li-ion-m50t-mit-kabeln-offenen-enden)
I suggest reserving a battery cavity of at least 91 × 78 × 52 mm, plus 25–30 mm for the cable exit.
The battery should be:
* Positioned low and near the system’s center of gravity
* Replaceable
* Protected from screws and sharp edges
* Retained without concentrated pressure on the cells
* Separated from the processor and power-board heat
* Cushioned using an appropriate flame-retardant material
8. IP2368 power board
The battery is connected to an IP2368 4S 100 W bidirectional USB-C PD module.
Published dimensions for the common module version are:
* PCB: 48 × 34 mm
* Maximum height: approximately 10 mm
* Four M2 mounting holes
* Hole-center spacing: 43.5 × 28.5 mm
* Approximate weight: 20 g
I suggest reserving at least 54 × 40 × 15 mm, with insulating standoffs and airflow around the MOSFETs and inductor.
Several IP2368 PCB layouts exist. I can provide my actual module, photographs and physical measurements before the final CAD is completed.
## 9. External enclosure, controls and connector requirements
The enclosure should have a professional and modern industrial design suitable for recording football matches beside an outdoor field.
Reliability, cooling, mechanical rigidity and accessibility are more important than making the enclosure excessively compact.
### 9.1 Preliminary enclosure dimensions
Based on the current internal components, the preliminary target external envelope is approximately:
* **Width:** 220 mm
* **Height:** 94 mm
* **Depth:** 120 mm
These dimensions are preliminary and may be adjusted after the internal layout study, thermal analysis and confirmation of the minimum practical camera spacing.
The enclosure should maintain rounded external corners, with a suggested corner radius of approximately **8–15 mm**.
The enclosure wall thickness should initially be:
* **2.5–3.0 mm** for a 3D-printed prototype
* Approximately **2.0–2.5 mm** for a future injection-molded version, subject to material and structural analysis
The enclosure must provide enough internal clearance for:
* ROCK 5B+ V1.2 with NVMe SSD
* Radxa Heatsink 6240B V2.0
* Two Radxa Camera 4K modules
* ENERpower 4S2P battery
* IP2368 power-management board
* Internal Wi-Fi, Bluetooth and 5G antennas
* SIM-card extension or accessible SIM-card holder
* HDMI-input connector access
* Wiring, FFC strain relief and service clearances
### 9.2 External control buttons
The enclosure must include two separate external push buttons:
1. **Power button**
2. **Bluetooth button**
The power button will be used to power the device on and off.
It should support:
* Short press for normal power control
* Long press for controlled or safe shutdown
The Bluetooth button will be used for:
* Enabling or disabling Bluetooth
* Starting Bluetooth pairing
* Recovering Bluetooth connectivity without opening the enclosure
The two buttons should be vertically aligned on the side or rear connector panel.
Recommended preliminary button dimensions are:
* **Visible button-cap size:** approximately 14 × 14 mm
* Acceptable button-cap range: **12–16 mm**
* Minimum button travel: approximately **0.5–1.0 mm**
* Minimum spacing between button caps: **6 mm**
* Preferred center-to-center spacing: approximately **20–24 mm**
* Raised protective border: approximately **1.0–1.5 mm**
* Button recess below the surrounding enclosure surface: approximately **0.5–1.0 mm**
Each button should have an engraved, molded or printed symbol:
* Standard power symbol for the power button
* Standard Bluetooth symbol for the Bluetooth button
The symbol should be at least approximately **7–9 mm high** and remain visible in low-light conditions.
The buttons must:
* Provide clear tactile feedback
* Be accessible while the device is mounted on a tripod
* Be protected against accidental activation
* Be suitable for repeated outdoor use
* Use an internal sealing membrane, gasket or sealed actuator
* Be replaceable without replacing the complete enclosure
* Be connected to the main board through removable connectors where practical
The final button cut-out must be based on the selected physical push-button component. Approximately **18 × 42 mm** should initially be reserved internally for the complete two-button control assembly, excluding wiring clearance.
### 9.3 HDMI input
The native HDMI input of the ROCK 5B+ must be accessible from outside the enclosure.
The HDMI opening should correspond to the ROCK 5B+ HDMI-input connector located near the board’s microSD-card area. However, the microSD-card slot itself does not need to be exposed externally.
The exterior panel should display only:
* **HDMI IN**
* **SIM CARD**
* Power button
* Bluetooth button
There should be no external microSD-card opening in this connector panel.
For a standard full-size HDMI Type-A connection, the preliminary enclosure opening should be approximately:
* **Connector opening:** 16 × 7 mm
* **Recommended recessed area:** approximately 24 × 13 mm
* **Minimum clearance around the connector:** 2–3 mm
* **Minimum internal cable-entry depth:** approximately 35 mm
* **Recommended clearance behind the connector:** approximately 40–45 mm where a straight HDMI plug is expected
The exact opening must be verified against the ROCK 5B+ V1.2 STEP model and a real HDMI cable.
The HDMI opening should:
* Allow insertion of common HDMI plugs with moderately thick molded housings
* Avoid mechanical loading of the ROCK 5B+ connector
* Include sufficient finger clearance
* Include cable strain relief or external cable support
* Remain accessible while the device is mounted
* Be clearly marked **HDMI IN**, rather than only HDMI
The mechanical designer should consider a short internal HDMI extension or panel-mount HDMI adapter if direct access to the board connector would place excessive force on the ROCK 5B+ PCB.
### 9.4 External SIM-card access
The SIM card must be removable from outside the enclosure without opening the main electronics compartment.
The preferred arrangement is an externally accessible SIM-card holder or a short SIM-card extension connected to the internal 5G modem.
The exact dimensions depend on whether the final modem uses:
* Nano-SIM
* Micro-SIM
* A push-push SIM holder
* A removable SIM tray
* A flexible SIM extension
For a nano-SIM tray, the preliminary external allocation should be approximately:
* **Visible SIM-tray width:** 14–18 mm
* **Visible SIM-tray height:** 2.5–4 mm
* **Recessed service area:** approximately 24 × 12 mm
* **Minimum finger or tool-access clearance:** 3 mm
* **Minimum spacing from the HDMI recess:** 8–10 mm
Approximately **25 × 20 × 10 mm** should initially be reserved internally for the SIM holder, extension connector and cable bend, subject to the selected component.
The opening must be clearly marked:
**SIM CARD**
The SIM card should not protrude from the enclosure when installed.
A push-push holder, captive tray or protected service door is preferred. The card must not be able to fall inside the enclosure during insertion or removal.
### 9.5 Connector and button-panel arrangement
The preferred arrangement from left to right is:
**HDMI IN — SIM CARD — POWER BUTTON — BLUETOOTH BUTTON**
The two buttons may instead be vertically arranged beside the HDMI and SIM openings when this produces a cleaner and more compact panel.
Recommended preliminary spacing:
* HDMI recess to SIM recess: at least **8–10 mm**
* SIM recess to button-protection area: at least **8 mm**
* Port-panel edge margin: at least **6 mm**
* Distance from external openings to major screw bosses: at least **5 mm**
* Distance from ports to ventilation openings: preferably at least **10 mm**
The connector panel should preferably be positioned on the side or rear of the enclosure so that connected cables do not obstruct:
* Either camera
* The panoramic field of view
* Cooling-air intake
* Warm-air exhaust
* Tripod mounting
* Battery-compartment access
* Camera-angle adjustment
### 9.6 Environmental protection
The HDMI and SIM openings should be protected by one of the following:
* One gasketed and hinged service door
* A removable gasketed connector cover
* Individual attached rubber covers
A single connector door covering both HDMI and SIM access is preferred for a clean commercial appearance.
The preliminary connector-door size should be approximately:
* **Width:** 65–80 mm
* **Height:** 28–35 mm
* **Door thickness:** approximately 2.5–3.0 mm for the prototype
* **Gasket width:** approximately 2–3 mm
The cover should:
* Remain captive when opened
* Include a positive closing mechanism
* Not interfere with the HDMI cable
* Allow replacement of the SIM card
* Protect the openings against dust and light rain
* Avoid placing excessive force on the HDMI connector
* Remain operable without removing the device from the tripod
The device is not initially required to be fully waterproof, but the enclosure should use gasketed construction suitable for outdoor use, dust and light rain.
### 9.7 Additional external requirements
The enclosure must also include:
* One accessible USB-C charging and power connection
* One accessible USB 3.0 connection
* External power, battery and recording indicators
* Recessed recovery or reset access
* Replaceable protective camera windows
* Threaded metal inserts
* Internal antennas with no externally protruding Wi-Fi or cellular antennas
* A 1/4-20 UNC metal tripod insert positioned near the complete system’s center of gravity
* Optional anti-rotation mounting points
* A removable battery compartment or battery-access panel
* A service cover for maintenance connectors that are not required during normal operation
The camera calibration must remain unchanged when opening the battery or electronics compartments.
The complete dual-camera mounting assembly should be removable as one rigid and calibrated unit.
The first prototype may be 3D printed, but the design should consider future:
* Low-volume CNC machining
* Urethane casting
* Vacuum casting
* Injection molding
All dimensions relating to connector cut-outs, push buttons, SIM holders and panel-mount extensions must be checked against the selected real components before the final STEP and STL files are released.
10. Requested phased quotation
To control the initial development cost, I would appreciate separate quotations for two phases.
Phase 1 – Mechanical architecture and concept
* Review of the supplied STEP models and physical hardware
* Internal component-layout study
* Minimum-parallax camera arrangement
* Adjustable 49–62° camera-mount concept
* Cooling and battery-placement concept
* Preliminary enclosure design
* Initial STEP assembly
* One or two design-review iterations
Phase 2 – Detailed design and prototype
* Final production-quality CAD
* Detailed camera adjustment and locking mechanism
* STEP and print-ready STL files
* 2D manufacturing drawings
* Fastener and purchased-component BOM
* Exploded assembly drawing
* Prototype fabrication support
* Design-for-manufacturing review
Please provide the estimated schedule and fixed-price or budget range for each phase separately.
Please let me know whether this project fits your mechanical and industrial-design capabilities and what additional information you require to prepare a quotation.
Best regards,
Mohamed Jâafar
France read less
I already have a functional electronics and software prototype using two synchronized 4K cameras and a Radxa ROCK 5B+. I am looking for assistance converting the handmade prototype into a professional, rigid and manufacturable enclosure.
The main requirements are:
* A rigid dual-camera mounting system that preserves calibration
* Minimum parallax between the two cameras
* Proper cooling for the ROCK 5B+
* Safe retention of the Li-ion battery
* Professional industrial design
* Prototype-ready STEP and STL files
The camera angle and optical geometry have already been established experimentally, so I do not need optical-system development from scratch.
1. Current calibrated camera geometry
The current handmade mount was measured through the deployed Hugin calibration:
* Camera A yaw: +24.97°
* Camera B yaw: −24.50°
* Measured optical-axis separation: 49.47°
* Relative pitch difference: approximately 2.86°
* Camera A: +1.06°
* Camera B: −1.80°
* Camera B residual roll: approximately 0.4°
These pitch and roll differences are manufacturing errors absorbed by calibration. A new professional mount should target equal pitch and zero relative roll rather than intentionally reproducing these errors.
For a new symmetric mount, the nominal camera positions should therefore be:
* Left camera yaw: +25°
* Right camera yaw: −25°
* Nominal optical-axis separation: 50°
* Equal pitch for both cameras
* Relative roll: 0°
The existing Hugin maps are baked from the current 49.47° geometry. The system will be recalibrated after installation in the new enclosure.
2. Camera field of view and mounting-angle options
Each Radxa Camera 4K uses the stock lens with the following published field of view:
* Horizontal FOV: 75° ±3°
* Vertical FOV: 59° ±2°
* Diagonal FOV: 88.2° ±5°
The relationship between camera separation, overlap and total field of view is approximately:
* 49.5° separation: approximately 25° overlap and 124° total coverage
* 55° separation: approximately 20° overlap and 130° total coverage
* 58–60° separation: approximately 15–17° overlap and 133–135° total coverage
* 65° separation: approximately 10° overlap, placing the seam too close to the soft and vignetted lens edges
* Above 67°: insufficient overlap for reliable stitching
For the current lenses, my preferred robust position is approximately 50°. This keeps the seam approximately 12.5° inside each lens edge, where image sharpness and brightness are better, particularly at night.
A 58–60° position may be useful as a maximum-coverage configuration, but I do not want the current lenses operated beyond approximately 62° separation.
I would like the mechanical design to provide:
* A rigid nominal position at 50° total separation
* Adjustment from approximately 49° to 62°
* Clear engraved or indexed positions at 50°, 55° and 60°
* A positive locking mechanism that cannot move after calibration
* Symmetric adjustment around the enclosure centerline
* Both lens centers at exactly the same vertical height
* Pitch adjustment of approximately ±5° for initial alignment
* Roll alignment as close to 0° as mechanically practical
The product may later use approximately 95° HFOV M12 lenses. With these wider lenses, approximately 62° separation would produce around 157° of total coverage with approximately 33° of overlap. The adjustable mount should therefore support the future 62° configuration.
3. Parallax and camera spacing
Minimizing parallax is more important than achieving sub-degree yaw accuracy.
The two camera lens entrance pupils should be positioned as close together as mechanically possible. The previous concept using approximately 140 mm lens spacing should not be used.
I would like 219 Design to determine the minimum practical lens-center separation using the camera STEP geometry. A preliminary target would be approximately 40–60 mm, subject to PCB, FFC connector, lens barrel and mounting-bracket clearances.
The mount must be very rigid. Any movement after Hugin calibration invalidates the baked stitching maps. The cameras should remain calibrated during transportation, tripod installation and normal outdoor operation.
Each camera should have an individual replaceable protective window positioned perpendicular to its optical axis. The clear aperture should be at least 18–20 mm to prevent vignetting.
4. Camera hardware
The system uses two identical Radxa Camera 4K modules with Sony IMX415 sensors.
Approximate dimensions for each camera:
* PCB: 32 × 32 mm
* PCB thickness: approximately 1.6 mm
* Mounting-hole pattern: 28 × 28 mm
* Complete camera depth: approximately 15.74 mm
* Lens barrel maximum diameter: approximately 14 mm
* Lens mount: M12 × 0.5
* FFC cable length: 150 mm
* MIPI CSI-2, four lanes
Camera documentation:
[https://dl.radxa.com/accessories/camera-4k/radxa_camera_4k_product_brief.pdf](https://dl.radxa.com/accessories/camera-4k/radxa_camera_4k_product_brief.pdf)
The two FFC camera cables require strain relief, controlled routing and no sharp folds. A minimum bend radius of approximately 5 mm should be maintained.
5. Main processor board
The main processor is:
* Radxa ROCK 5B+
* Hardware revision V1.2
* Reference PCB envelope: approximately 100.19 × 74.24 mm
* One M.2 2280 NVMe SSD installed underneath
* Two MIPI-CSI camera connections
The official V1.2 STEP model must be used for exact mounting holes, connector positions and component heights. The older ROCK 5B CAD model is not interchangeable with my ROCK 5B+ V1.2.
Official mechanical resources:
[https://docs.radxa.com/en/rock5/rock5b/download](https://docs.radxa.com/en/rock5/rock5b/download)
Direct V1.2 STEP model:
[https://dl.radxa.com/rock5/5b%2B/docs/hw/rock5bp_pcba_3d_V1_2_20250314.stp](https://dl.radxa.com/rock5/5b%2B/docs/hw/rock5bp_pcba_3d_V1_2_20250314.stp)
6. Cooling
The ROCK 5B+ uses the official Radxa Heatsink 6240B V2.0:
* Dimensions: 62 × 40 × 9 mm
* Integrated 5 V fan
* Fan speed: up to approximately 7,000 RPM
* At least 15 mm of unobstructed air should remain above the fan intake
The enclosure needs a defined cool-air intake and warm-air exhaust path. The battery must not be placed in the ROCK 5B+ hot-air exhaust.
Heatsink documentation:
[https://docs.radxa.com/en/accessories/heatsink-case/heatsink-6240b](https://docs.radxa.com/en/accessories/heatsink-case/heatsink-6240b)
7. Battery
I have purchased an ENERpower 4S2P Li-ion battery:
* Cells: INR21700-M50T
* Configuration: 4S2P
* Nominal voltage: 14.4–14.8 V
* Fully charged voltage: 16.8 V
* Capacity: 10,000 mAh
* Energy: approximately 144–148 Wh
* Dimensions: 85 × 72 × 46 mm
* Weight: approximately 600 g
* Integrated 8 A protection PCB
* Published maximum power: 115 W
* Open-ended charging and discharging cables
* Cable length: approximately 100–150 mm
Battery documentation:
[https://enerprof.de/en/products/enerpower-4s2p-akku-14-4v-14-8v-10000-mah-li-ion-m50t-mit-kabeln-offenen-enden](https://enerprof.de/en/products/enerpower-4s2p-akku-14-4v-14-8v-10000-mah-li-ion-m50t-mit-kabeln-offenen-enden)
I suggest reserving a battery cavity of at least 91 × 78 × 52 mm, plus 25–30 mm for the cable exit.
The battery should be:
* Positioned low and near the system’s center of gravity
* Replaceable
* Protected from screws and sharp edges
* Retained without concentrated pressure on the cells
* Separated from the processor and power-board heat
* Cushioned using an appropriate flame-retardant material
8. IP2368 power board
The battery is connected to an IP2368 4S 100 W bidirectional USB-C PD module.
Published dimensions for the common module version are:
* PCB: 48 × 34 mm
* Maximum height: approximately 10 mm
* Four M2 mounting holes
* Hole-center spacing: 43.5 × 28.5 mm
* Approximate weight: 20 g
I suggest reserving at least 54 × 40 × 15 mm, with insulating standoffs and airflow around the MOSFETs and inductor.
Several IP2368 PCB layouts exist. I can provide my actual module, photographs and physical measurements before the final CAD is completed.
## 9. External enclosure, controls and connector requirements
The enclosure should have a professional and modern industrial design suitable for recording football matches beside an outdoor field.
Reliability, cooling, mechanical rigidity and accessibility are more important than making the enclosure excessively compact.
### 9.1 Preliminary enclosure dimensions
Based on the current internal components, the preliminary target external envelope is approximately:
* **Width:** 220 mm
* **Height:** 94 mm
* **Depth:** 120 mm
These dimensions are preliminary and may be adjusted after the internal layout study, thermal analysis and confirmation of the minimum practical camera spacing.
The enclosure should maintain rounded external corners, with a suggested corner radius of approximately **8–15 mm**.
The enclosure wall thickness should initially be:
* **2.5–3.0 mm** for a 3D-printed prototype
* Approximately **2.0–2.5 mm** for a future injection-molded version, subject to material and structural analysis
The enclosure must provide enough internal clearance for:
* ROCK 5B+ V1.2 with NVMe SSD
* Radxa Heatsink 6240B V2.0
* Two Radxa Camera 4K modules
* ENERpower 4S2P battery
* IP2368 power-management board
* Internal Wi-Fi, Bluetooth and 5G antennas
* SIM-card extension or accessible SIM-card holder
* HDMI-input connector access
* Wiring, FFC strain relief and service clearances
### 9.2 External control buttons
The enclosure must include two separate external push buttons:
1. **Power button**
2. **Bluetooth button**
The power button will be used to power the device on and off.
It should support:
* Short press for normal power control
* Long press for controlled or safe shutdown
The Bluetooth button will be used for:
* Enabling or disabling Bluetooth
* Starting Bluetooth pairing
* Recovering Bluetooth connectivity without opening the enclosure
The two buttons should be vertically aligned on the side or rear connector panel.
Recommended preliminary button dimensions are:
* **Visible button-cap size:** approximately 14 × 14 mm
* Acceptable button-cap range: **12–16 mm**
* Minimum button travel: approximately **0.5–1.0 mm**
* Minimum spacing between button caps: **6 mm**
* Preferred center-to-center spacing: approximately **20–24 mm**
* Raised protective border: approximately **1.0–1.5 mm**
* Button recess below the surrounding enclosure surface: approximately **0.5–1.0 mm**
Each button should have an engraved, molded or printed symbol:
* Standard power symbol for the power button
* Standard Bluetooth symbol for the Bluetooth button
The symbol should be at least approximately **7–9 mm high** and remain visible in low-light conditions.
The buttons must:
* Provide clear tactile feedback
* Be accessible while the device is mounted on a tripod
* Be protected against accidental activation
* Be suitable for repeated outdoor use
* Use an internal sealing membrane, gasket or sealed actuator
* Be replaceable without replacing the complete enclosure
* Be connected to the main board through removable connectors where practical
The final button cut-out must be based on the selected physical push-button component. Approximately **18 × 42 mm** should initially be reserved internally for the complete two-button control assembly, excluding wiring clearance.
### 9.3 HDMI input
The native HDMI input of the ROCK 5B+ must be accessible from outside the enclosure.
The HDMI opening should correspond to the ROCK 5B+ HDMI-input connector located near the board’s microSD-card area. However, the microSD-card slot itself does not need to be exposed externally.
The exterior panel should display only:
* **HDMI IN**
* **SIM CARD**
* Power button
* Bluetooth button
There should be no external microSD-card opening in this connector panel.
For a standard full-size HDMI Type-A connection, the preliminary enclosure opening should be approximately:
* **Connector opening:** 16 × 7 mm
* **Recommended recessed area:** approximately 24 × 13 mm
* **Minimum clearance around the connector:** 2–3 mm
* **Minimum internal cable-entry depth:** approximately 35 mm
* **Recommended clearance behind the connector:** approximately 40–45 mm where a straight HDMI plug is expected
The exact opening must be verified against the ROCK 5B+ V1.2 STEP model and a real HDMI cable.
The HDMI opening should:
* Allow insertion of common HDMI plugs with moderately thick molded housings
* Avoid mechanical loading of the ROCK 5B+ connector
* Include sufficient finger clearance
* Include cable strain relief or external cable support
* Remain accessible while the device is mounted
* Be clearly marked **HDMI IN**, rather than only HDMI
The mechanical designer should consider a short internal HDMI extension or panel-mount HDMI adapter if direct access to the board connector would place excessive force on the ROCK 5B+ PCB.
### 9.4 External SIM-card access
The SIM card must be removable from outside the enclosure without opening the main electronics compartment.
The preferred arrangement is an externally accessible SIM-card holder or a short SIM-card extension connected to the internal 5G modem.
The exact dimensions depend on whether the final modem uses:
* Nano-SIM
* Micro-SIM
* A push-push SIM holder
* A removable SIM tray
* A flexible SIM extension
For a nano-SIM tray, the preliminary external allocation should be approximately:
* **Visible SIM-tray width:** 14–18 mm
* **Visible SIM-tray height:** 2.5–4 mm
* **Recessed service area:** approximately 24 × 12 mm
* **Minimum finger or tool-access clearance:** 3 mm
* **Minimum spacing from the HDMI recess:** 8–10 mm
Approximately **25 × 20 × 10 mm** should initially be reserved internally for the SIM holder, extension connector and cable bend, subject to the selected component.
The opening must be clearly marked:
**SIM CARD**
The SIM card should not protrude from the enclosure when installed.
A push-push holder, captive tray or protected service door is preferred. The card must not be able to fall inside the enclosure during insertion or removal.
### 9.5 Connector and button-panel arrangement
The preferred arrangement from left to right is:
**HDMI IN — SIM CARD — POWER BUTTON — BLUETOOTH BUTTON**
The two buttons may instead be vertically arranged beside the HDMI and SIM openings when this produces a cleaner and more compact panel.
Recommended preliminary spacing:
* HDMI recess to SIM recess: at least **8–10 mm**
* SIM recess to button-protection area: at least **8 mm**
* Port-panel edge margin: at least **6 mm**
* Distance from external openings to major screw bosses: at least **5 mm**
* Distance from ports to ventilation openings: preferably at least **10 mm**
The connector panel should preferably be positioned on the side or rear of the enclosure so that connected cables do not obstruct:
* Either camera
* The panoramic field of view
* Cooling-air intake
* Warm-air exhaust
* Tripod mounting
* Battery-compartment access
* Camera-angle adjustment
### 9.6 Environmental protection
The HDMI and SIM openings should be protected by one of the following:
* One gasketed and hinged service door
* A removable gasketed connector cover
* Individual attached rubber covers
A single connector door covering both HDMI and SIM access is preferred for a clean commercial appearance.
The preliminary connector-door size should be approximately:
* **Width:** 65–80 mm
* **Height:** 28–35 mm
* **Door thickness:** approximately 2.5–3.0 mm for the prototype
* **Gasket width:** approximately 2–3 mm
The cover should:
* Remain captive when opened
* Include a positive closing mechanism
* Not interfere with the HDMI cable
* Allow replacement of the SIM card
* Protect the openings against dust and light rain
* Avoid placing excessive force on the HDMI connector
* Remain operable without removing the device from the tripod
The device is not initially required to be fully waterproof, but the enclosure should use gasketed construction suitable for outdoor use, dust and light rain.
### 9.7 Additional external requirements
The enclosure must also include:
* One accessible USB-C charging and power connection
* One accessible USB 3.0 connection
* External power, battery and recording indicators
* Recessed recovery or reset access
* Replaceable protective camera windows
* Threaded metal inserts
* Internal antennas with no externally protruding Wi-Fi or cellular antennas
* A 1/4-20 UNC metal tripod insert positioned near the complete system’s center of gravity
* Optional anti-rotation mounting points
* A removable battery compartment or battery-access panel
* A service cover for maintenance connectors that are not required during normal operation
The camera calibration must remain unchanged when opening the battery or electronics compartments.
The complete dual-camera mounting assembly should be removable as one rigid and calibrated unit.
The first prototype may be 3D printed, but the design should consider future:
* Low-volume CNC machining
* Urethane casting
* Vacuum casting
* Injection molding
All dimensions relating to connector cut-outs, push buttons, SIM holders and panel-mount extensions must be checked against the selected real components before the final STEP and STL files are released.
10. Requested phased quotation
To control the initial development cost, I would appreciate separate quotations for two phases.
Phase 1 – Mechanical architecture and concept
* Review of the supplied STEP models and physical hardware
* Internal component-layout study
* Minimum-parallax camera arrangement
* Adjustable 49–62° camera-mount concept
* Cooling and battery-placement concept
* Preliminary enclosure design
* Initial STEP assembly
* One or two design-review iterations
Phase 2 – Detailed design and prototype
* Final production-quality CAD
* Detailed camera adjustment and locking mechanism
* STEP and print-ready STL files
* 2D manufacturing drawings
* Fastener and purchased-component BOM
* Exploded assembly drawing
* Prototype fabrication support
* Design-for-manufacturing review
Please provide the estimated schedule and fixed-price or budget range for each phase separately.
Please let me know whether this project fits your mechanical and industrial-design capabilities and what additional information you require to prepare a quotation.
Best regards,
Mohamed Jâafar
France read less
My name is Mohamed Jâafar, and I am based in France. I am developing a self-contained, battery-powered panoramic camera for recording, streaming and analyzing football matches.
I already have a functional electronics and software prototype using two synchronized 4K cameras and a Radxa ROCK 5B+. I am looking for assistance converting the handmade prototype into a professional, rigid and manufact... read more
I already have a functional electronics and software prototype using two synchronized 4K cameras and a Radxa ROCK 5B+. I am looking for assistance converting the handmade prototype into a professional, rigid and manufact... read more
My name is Mohamed Jâafar, and I am based in France. I am developing a self-contained, battery-powered panoramic camera for recording, streaming and analyzing football matches.
I already have a functional electronics and software prototype using two synchronized 4K cameras and a Radxa ROCK 5B+. I am looking for assistance converting the handmade prototype into a professional, rigid and manufacturable enclosure.
The main requirements are:
* A rigid dual-camera mounting system that preserves calibration
* Minimum parallax between the two cameras
* Proper cooling for the ROCK 5B+
* Safe retention of the Li-ion battery
* Professional industrial design
* Prototype-ready STEP and STL files
The camera angle and optical geometry have already been established experimentally, so I do not need optical-system development from scratch.
1. Current calibrated camera geometry
The current handmade mount was measured through the deployed Hugin calibration:
* Camera A yaw: +24.97°
* Camera B yaw: −24.50°
* Measured optical-axis separation: 49.47°
* Relative pitch difference: approximately 2.86°
* Camera A: +1.06°
* Camera B: −1.80°
* Camera B residual roll: approximately 0.4°
These pitch and roll differences are manufacturing errors absorbed by calibration. A new professional mount should target equal pitch and zero relative roll rather than intentionally reproducing these errors.
For a new symmetric mount, the nominal camera positions should therefore be:
* Left camera yaw: +25°
* Right camera yaw: −25°
* Nominal optical-axis separation: 50°
* Equal pitch for both cameras
* Relative roll: 0°
The existing Hugin maps are baked from the current 49.47° geometry. The system will be recalibrated after installation in the new enclosure.
2. Camera field of view and mounting-angle options
Each Radxa Camera 4K uses the stock lens with the following published field of view:
* Horizontal FOV: 75° ±3°
* Vertical FOV: 59° ±2°
* Diagonal FOV: 88.2° ±5°
The relationship between camera separation, overlap and total field of view is approximately:
* 49.5° separation: approximately 25° overlap and 124° total coverage
* 55° separation: approximately 20° overlap and 130° total coverage
* 58–60° separation: approximately 15–17° overlap and 133–135° total coverage
* 65° separation: approximately 10° overlap, placing the seam too close to the soft and vignetted lens edges
* Above 67°: insufficient overlap for reliable stitching
For the current lenses, my preferred robust position is approximately 50°. This keeps the seam approximately 12.5° inside each lens edge, where image sharpness and brightness are better, particularly at night.
A 58–60° position may be useful as a maximum-coverage configuration, but I do not want the current lenses operated beyond approximately 62° separation.
I would like the mechanical design to provide:
* A rigid nominal position at 50° total separation
* Adjustment from approximately 49° to 62°
* Clear engraved or indexed positions at 50°, 55° and 60°
* A positive locking mechanism that cannot move after calibration
* Symmetric adjustment around the enclosure centerline
* Both lens centers at exactly the same vertical height
* Pitch adjustment of approximately ±5° for initial alignment
* Roll alignment as close to 0° as mechanically practical
The product may later use approximately 95° HFOV M12 lenses. With these wider lenses, approximately 62° separation would produce around 157° of total coverage with approximately 33° of overlap. The adjustable mount should therefore support the future 62° configuration.
3. Parallax and camera spacing
Minimizing parallax is more important than achieving sub-degree yaw accuracy.
The two camera lens entrance pupils should be positioned as close together as mechanically possible. The previous concept using approximately 140 mm lens spacing should not be used.
I would like 219 Design to determine the minimum practical lens-center separation using the camera STEP geometry. A preliminary target would be approximately 40–60 mm, subject to PCB, FFC connector, lens barrel and mounting-bracket clearances.
The mount must be very rigid. Any movement after Hugin calibration invalidates the baked stitching maps. The cameras should remain calibrated during transportation, tripod installation and normal outdoor operation.
Each camera should have an individual replaceable protective window positioned perpendicular to its optical axis. The clear aperture should be at least 18–20 mm to prevent vignetting.
4. Camera hardware
The system uses two identical Radxa Camera 4K modules with Sony IMX415 sensors.
Approximate dimensions for each camera:
* PCB: 32 × 32 mm
* PCB thickness: approximately 1.6 mm
* Mounting-hole pattern: 28 × 28 mm
* Complete camera depth: approximately 15.74 mm
* Lens barrel maximum diameter: approximately 14 mm
* Lens mount: M12 × 0.5
* FFC cable length: 150 mm
* MIPI CSI-2, four lanes
Camera documentation:
[https://dl.radxa.com/accessories/camera-4k/radxa_camera_4k_product_brief.pdf](https://dl.radxa.com/accessories/camera-4k/radxa_camera_4k_product_brief.pdf)
The two FFC camera cables require strain relief, controlled routing and no sharp folds. A minimum bend radius of approximately 5 mm should be maintained.
5. Main processor board
The main processor is:
* Radxa ROCK 5B+
* Hardware revision V1.2
* Reference PCB envelope: approximately 100.19 × 74.24 mm
* One M.2 2280 NVMe SSD installed underneath
* Two MIPI-CSI camera connections
The official V1.2 STEP model must be used for exact mounting holes, connector positions and component heights. The older ROCK 5B CAD model is not interchangeable with my ROCK 5B+ V1.2.
Official mechanical resources:
[https://docs.radxa.com/en/rock5/rock5b/download](https://docs.radxa.com/en/rock5/rock5b/download)
Direct V1.2 STEP model:
[https://dl.radxa.com/rock5/5b%2B/docs/hw/rock5bp_pcba_3d_V1_2_20250314.stp](https://dl.radxa.com/rock5/5b%2B/docs/hw/rock5bp_pcba_3d_V1_2_20250314.stp)
6. Cooling
The ROCK 5B+ uses the official Radxa Heatsink 6240B V2.0:
* Dimensions: 62 × 40 × 9 mm
* Integrated 5 V fan
* Fan speed: up to approximately 7,000 RPM
* At least 15 mm of unobstructed air should remain above the fan intake
The enclosure needs a defined cool-air intake and warm-air exhaust path. The battery must not be placed in the ROCK 5B+ hot-air exhaust.
Heatsink documentation:
[https://docs.radxa.com/en/accessories/heatsink-case/heatsink-6240b](https://docs.radxa.com/en/accessories/heatsink-case/heatsink-6240b)
7. Battery
I have purchased an ENERpower 4S2P Li-ion battery:
* Cells: INR21700-M50T
* Configuration: 4S2P
* Nominal voltage: 14.4–14.8 V
* Fully charged voltage: 16.8 V
* Capacity: 10,000 mAh
* Energy: approximately 144–148 Wh
* Dimensions: 85 × 72 × 46 mm
* Weight: approximately 600 g
* Integrated 8 A protection PCB
* Published maximum power: 115 W
* Open-ended charging and discharging cables
* Cable length: approximately 100–150 mm
Battery documentation:
[https://enerprof.de/en/products/enerpower-4s2p-akku-14-4v-14-8v-10000-mah-li-ion-m50t-mit-kabeln-offenen-enden](https://enerprof.de/en/products/enerpower-4s2p-akku-14-4v-14-8v-10000-mah-li-ion-m50t-mit-kabeln-offenen-enden)
I suggest reserving a battery cavity of at least 91 × 78 × 52 mm, plus 25–30 mm for the cable exit.
The battery should be:
* Positioned low and near the system’s center of gravity
* Replaceable
* Protected from screws and sharp edges
* Retained without concentrated pressure on the cells
* Separated from the processor and power-board heat
* Cushioned using an appropriate flame-retardant material
8. IP2368 power board
The battery is connected to an IP2368 4S 100 W bidirectional USB-C PD module.
Published dimensions for the common module version are:
* PCB: 48 × 34 mm
* Maximum height: approximately 10 mm
* Four M2 mounting holes
* Hole-center spacing: 43.5 × 28.5 mm
* Approximate weight: 20 g
I suggest reserving at least 54 × 40 × 15 mm, with insulating standoffs and airflow around the MOSFETs and inductor.
Several IP2368 PCB layouts exist. I can provide my actual module, photographs and physical measurements before the final CAD is completed.
## 9. External enclosure, controls and connector requirements
The enclosure should have a professional and modern industrial design suitable for recording football matches beside an outdoor field.
Reliability, cooling, mechanical rigidity and accessibility are more important than making the enclosure excessively compact.
### 9.1 Preliminary enclosure dimensions
Based on the current internal components, the preliminary target external envelope is approximately:
* **Width:** 220 mm
* **Height:** 94 mm
* **Depth:** 120 mm
These dimensions are preliminary and may be adjusted after the internal layout study, thermal analysis and confirmation of the minimum practical camera spacing.
The enclosure should maintain rounded external corners, with a suggested corner radius of approximately **8–15 mm**.
The enclosure wall thickness should initially be:
* **2.5–3.0 mm** for a 3D-printed prototype
* Approximately **2.0–2.5 mm** for a future injection-molded version, subject to material and structural analysis
The enclosure must provide enough internal clearance for:
* ROCK 5B+ V1.2 with NVMe SSD
* Radxa Heatsink 6240B V2.0
* Two Radxa Camera 4K modules
* ENERpower 4S2P battery
* IP2368 power-management board
* Internal Wi-Fi, Bluetooth and 5G antennas
* SIM-card extension or accessible SIM-card holder
* HDMI-input connector access
* Wiring, FFC strain relief and service clearances
### 9.2 External control buttons
The enclosure must include two separate external push buttons:
1. **Power button**
2. **Bluetooth button**
The power button will be used to power the device on and off.
It should support:
* Short press for normal power control
* Long press for controlled or safe shutdown
The Bluetooth button will be used for:
* Enabling or disabling Bluetooth
* Starting Bluetooth pairing
* Recovering Bluetooth connectivity without opening the enclosure
The two buttons should be vertically aligned on the side or rear connector panel.
Recommended preliminary button dimensions are:
* **Visible button-cap size:** approximately 14 × 14 mm
* Acceptable button-cap range: **12–16 mm**
* Minimum button travel: approximately **0.5–1.0 mm**
* Minimum spacing between button caps: **6 mm**
* Preferred center-to-center spacing: approximately **20–24 mm**
* Raised protective border: approximately **1.0–1.5 mm**
* Button recess below the surrounding enclosure surface: approximately **0.5–1.0 mm**
Each button should have an engraved, molded or printed symbol:
* Standard power symbol for the power button
* Standard Bluetooth symbol for the Bluetooth button
The symbol should be at least approximately **7–9 mm high** and remain visible in low-light conditions.
The buttons must:
* Provide clear tactile feedback
* Be accessible while the device is mounted on a tripod
* Be protected against accidental activation
* Be suitable for repeated outdoor use
* Use an internal sealing membrane, gasket or sealed actuator
* Be replaceable without replacing the complete enclosure
* Be connected to the main board through removable connectors where practical
The final button cut-out must be based on the selected physical push-button component. Approximately **18 × 42 mm** should initially be reserved internally for the complete two-button control assembly, excluding wiring clearance.
### 9.3 HDMI input
The native HDMI input of the ROCK 5B+ must be accessible from outside the enclosure.
The HDMI opening should correspond to the ROCK 5B+ HDMI-input connector located near the board’s microSD-card area. However, the microSD-card slot itself does not need to be exposed externally.
The exterior panel should display only:
* **HDMI IN**
* **SIM CARD**
* Power button
* Bluetooth button
There should be no external microSD-card opening in this connector panel.
For a standard full-size HDMI Type-A connection, the preliminary enclosure opening should be approximately:
* **Connector opening:** 16 × 7 mm
* **Recommended recessed area:** approximately 24 × 13 mm
* **Minimum clearance around the connector:** 2–3 mm
* **Minimum internal cable-entry depth:** approximately 35 mm
* **Recommended clearance behind the connector:** approximately 40–45 mm where a straight HDMI plug is expected
The exact opening must be verified against the ROCK 5B+ V1.2 STEP model and a real HDMI cable.
The HDMI opening should:
* Allow insertion of common HDMI plugs with moderately thick molded housings
* Avoid mechanical loading of the ROCK 5B+ connector
* Include sufficient finger clearance
* Include cable strain relief or external cable support
* Remain accessible while the device is mounted
* Be clearly marked **HDMI IN**, rather than only HDMI
The mechanical designer should consider a short internal HDMI extension or panel-mount HDMI adapter if direct access to the board connector would place excessive force on the ROCK 5B+ PCB.
### 9.4 External SIM-card access
The SIM card must be removable from outside the enclosure without opening the main electronics compartment.
The preferred arrangement is an externally accessible SIM-card holder or a short SIM-card extension connected to the internal 5G modem.
The exact dimensions depend on whether the final modem uses:
* Nano-SIM
* Micro-SIM
* A push-push SIM holder
* A removable SIM tray
* A flexible SIM extension
For a nano-SIM tray, the preliminary external allocation should be approximately:
* **Visible SIM-tray width:** 14–18 mm
* **Visible SIM-tray height:** 2.5–4 mm
* **Recessed service area:** approximately 24 × 12 mm
* **Minimum finger or tool-access clearance:** 3 mm
* **Minimum spacing from the HDMI recess:** 8–10 mm
Approximately **25 × 20 × 10 mm** should initially be reserved internally for the SIM holder, extension connector and cable bend, subject to the selected component.
The opening must be clearly marked:
**SIM CARD**
The SIM card should not protrude from the enclosure when installed.
A push-push holder, captive tray or protected service door is preferred. The card must not be able to fall inside the enclosure during insertion or removal.
### 9.5 Connector and button-panel arrangement
The preferred arrangement from left to right is:
**HDMI IN — SIM CARD — POWER BUTTON — BLUETOOTH BUTTON**
The two buttons may instead be vertically arranged beside the HDMI and SIM openings when this produces a cleaner and more compact panel.
Recommended preliminary spacing:
* HDMI recess to SIM recess: at least **8–10 mm**
* SIM recess to button-protection area: at least **8 mm**
* Port-panel edge margin: at least **6 mm**
* Distance from external openings to major screw bosses: at least **5 mm**
* Distance from ports to ventilation openings: preferably at least **10 mm**
The connector panel should preferably be positioned on the side or rear of the enclosure so that connected cables do not obstruct:
* Either camera
* The panoramic field of view
* Cooling-air intake
* Warm-air exhaust
* Tripod mounting
* Battery-compartment access
* Camera-angle adjustment
### 9.6 Environmental protection
The HDMI and SIM openings should be protected by one of the following:
* One gasketed and hinged service door
* A removable gasketed connector cover
* Individual attached rubber covers
A single connector door covering both HDMI and SIM access is preferred for a clean commercial appearance.
The preliminary connector-door size should be approximately:
* **Width:** 65–80 mm
* **Height:** 28–35 mm
* **Door thickness:** approximately 2.5–3.0 mm for the prototype
* **Gasket width:** approximately 2–3 mm
The cover should:
* Remain captive when opened
* Include a positive closing mechanism
* Not interfere with the HDMI cable
* Allow replacement of the SIM card
* Protect the openings against dust and light rain
* Avoid placing excessive force on the HDMI connector
* Remain operable without removing the device from the tripod
The device is not initially required to be fully waterproof, but the enclosure should use gasketed construction suitable for outdoor use, dust and light rain.
### 9.7 Additional external requirements
The enclosure must also include:
* One accessible USB-C charging and power connection
* One accessible USB 3.0 connection
* External power, battery and recording indicators
* Recessed recovery or reset access
* Replaceable protective camera windows
* Threaded metal inserts
* Internal antennas with no externally protruding Wi-Fi or cellular antennas
* A 1/4-20 UNC metal tripod insert positioned near the complete system’s center of gravity
* Optional anti-rotation mounting points
* A removable battery compartment or battery-access panel
* A service cover for maintenance connectors that are not required during normal operation
The camera calibration must remain unchanged when opening the battery or electronics compartments.
The complete dual-camera mounting assembly should be removable as one rigid and calibrated unit.
The first prototype may be 3D printed, but the design should consider future:
* Low-volume CNC machining
* Urethane casting
* Vacuum casting
* Injection molding
All dimensions relating to connector cut-outs, push buttons, SIM holders and panel-mount extensions must be checked against the selected real components before the final STEP and STL files are released.
10. Requested phased quotation
To control the initial development cost, I would appreciate separate quotations for two phases.
Phase 1 – Mechanical architecture and concept
* Review of the supplied STEP models and physical hardware
* Internal component-layout study
* Minimum-parallax camera arrangement
* Adjustable 49–62° camera-mount concept
* Cooling and battery-placement concept
* Preliminary enclosure design
* Initial STEP assembly
* One or two design-review iterations
Phase 2 – Detailed design and prototype
* Final production-quality CAD
* Detailed camera adjustment and locking mechanism
* STEP and print-ready STL files
* 2D manufacturing drawings
* Fastener and purchased-component BOM
* Exploded assembly drawing
* Prototype fabrication support
* Design-for-manufacturing review
Please provide the estimated schedule and fixed-price or budget range for each phase separately.
Please let me know whether this project fits your mechanical and industrial-design capabilities and what additional information you require to prepare a quotation.
Best regards,
Mohamed Jâafar
France read less
I already have a functional electronics and software prototype using two synchronized 4K cameras and a Radxa ROCK 5B+. I am looking for assistance converting the handmade prototype into a professional, rigid and manufacturable enclosure.
The main requirements are:
* A rigid dual-camera mounting system that preserves calibration
* Minimum parallax between the two cameras
* Proper cooling for the ROCK 5B+
* Safe retention of the Li-ion battery
* Professional industrial design
* Prototype-ready STEP and STL files
The camera angle and optical geometry have already been established experimentally, so I do not need optical-system development from scratch.
1. Current calibrated camera geometry
The current handmade mount was measured through the deployed Hugin calibration:
* Camera A yaw: +24.97°
* Camera B yaw: −24.50°
* Measured optical-axis separation: 49.47°
* Relative pitch difference: approximately 2.86°
* Camera A: +1.06°
* Camera B: −1.80°
* Camera B residual roll: approximately 0.4°
These pitch and roll differences are manufacturing errors absorbed by calibration. A new professional mount should target equal pitch and zero relative roll rather than intentionally reproducing these errors.
For a new symmetric mount, the nominal camera positions should therefore be:
* Left camera yaw: +25°
* Right camera yaw: −25°
* Nominal optical-axis separation: 50°
* Equal pitch for both cameras
* Relative roll: 0°
The existing Hugin maps are baked from the current 49.47° geometry. The system will be recalibrated after installation in the new enclosure.
2. Camera field of view and mounting-angle options
Each Radxa Camera 4K uses the stock lens with the following published field of view:
* Horizontal FOV: 75° ±3°
* Vertical FOV: 59° ±2°
* Diagonal FOV: 88.2° ±5°
The relationship between camera separation, overlap and total field of view is approximately:
* 49.5° separation: approximately 25° overlap and 124° total coverage
* 55° separation: approximately 20° overlap and 130° total coverage
* 58–60° separation: approximately 15–17° overlap and 133–135° total coverage
* 65° separation: approximately 10° overlap, placing the seam too close to the soft and vignetted lens edges
* Above 67°: insufficient overlap for reliable stitching
For the current lenses, my preferred robust position is approximately 50°. This keeps the seam approximately 12.5° inside each lens edge, where image sharpness and brightness are better, particularly at night.
A 58–60° position may be useful as a maximum-coverage configuration, but I do not want the current lenses operated beyond approximately 62° separation.
I would like the mechanical design to provide:
* A rigid nominal position at 50° total separation
* Adjustment from approximately 49° to 62°
* Clear engraved or indexed positions at 50°, 55° and 60°
* A positive locking mechanism that cannot move after calibration
* Symmetric adjustment around the enclosure centerline
* Both lens centers at exactly the same vertical height
* Pitch adjustment of approximately ±5° for initial alignment
* Roll alignment as close to 0° as mechanically practical
The product may later use approximately 95° HFOV M12 lenses. With these wider lenses, approximately 62° separation would produce around 157° of total coverage with approximately 33° of overlap. The adjustable mount should therefore support the future 62° configuration.
3. Parallax and camera spacing
Minimizing parallax is more important than achieving sub-degree yaw accuracy.
The two camera lens entrance pupils should be positioned as close together as mechanically possible. The previous concept using approximately 140 mm lens spacing should not be used.
I would like 219 Design to determine the minimum practical lens-center separation using the camera STEP geometry. A preliminary target would be approximately 40–60 mm, subject to PCB, FFC connector, lens barrel and mounting-bracket clearances.
The mount must be very rigid. Any movement after Hugin calibration invalidates the baked stitching maps. The cameras should remain calibrated during transportation, tripod installation and normal outdoor operation.
Each camera should have an individual replaceable protective window positioned perpendicular to its optical axis. The clear aperture should be at least 18–20 mm to prevent vignetting.
4. Camera hardware
The system uses two identical Radxa Camera 4K modules with Sony IMX415 sensors.
Approximate dimensions for each camera:
* PCB: 32 × 32 mm
* PCB thickness: approximately 1.6 mm
* Mounting-hole pattern: 28 × 28 mm
* Complete camera depth: approximately 15.74 mm
* Lens barrel maximum diameter: approximately 14 mm
* Lens mount: M12 × 0.5
* FFC cable length: 150 mm
* MIPI CSI-2, four lanes
Camera documentation:
[https://dl.radxa.com/accessories/camera-4k/radxa_camera_4k_product_brief.pdf](https://dl.radxa.com/accessories/camera-4k/radxa_camera_4k_product_brief.pdf)
The two FFC camera cables require strain relief, controlled routing and no sharp folds. A minimum bend radius of approximately 5 mm should be maintained.
5. Main processor board
The main processor is:
* Radxa ROCK 5B+
* Hardware revision V1.2
* Reference PCB envelope: approximately 100.19 × 74.24 mm
* One M.2 2280 NVMe SSD installed underneath
* Two MIPI-CSI camera connections
The official V1.2 STEP model must be used for exact mounting holes, connector positions and component heights. The older ROCK 5B CAD model is not interchangeable with my ROCK 5B+ V1.2.
Official mechanical resources:
[https://docs.radxa.com/en/rock5/rock5b/download](https://docs.radxa.com/en/rock5/rock5b/download)
Direct V1.2 STEP model:
[https://dl.radxa.com/rock5/5b%2B/docs/hw/rock5bp_pcba_3d_V1_2_20250314.stp](https://dl.radxa.com/rock5/5b%2B/docs/hw/rock5bp_pcba_3d_V1_2_20250314.stp)
6. Cooling
The ROCK 5B+ uses the official Radxa Heatsink 6240B V2.0:
* Dimensions: 62 × 40 × 9 mm
* Integrated 5 V fan
* Fan speed: up to approximately 7,000 RPM
* At least 15 mm of unobstructed air should remain above the fan intake
The enclosure needs a defined cool-air intake and warm-air exhaust path. The battery must not be placed in the ROCK 5B+ hot-air exhaust.
Heatsink documentation:
[https://docs.radxa.com/en/accessories/heatsink-case/heatsink-6240b](https://docs.radxa.com/en/accessories/heatsink-case/heatsink-6240b)
7. Battery
I have purchased an ENERpower 4S2P Li-ion battery:
* Cells: INR21700-M50T
* Configuration: 4S2P
* Nominal voltage: 14.4–14.8 V
* Fully charged voltage: 16.8 V
* Capacity: 10,000 mAh
* Energy: approximately 144–148 Wh
* Dimensions: 85 × 72 × 46 mm
* Weight: approximately 600 g
* Integrated 8 A protection PCB
* Published maximum power: 115 W
* Open-ended charging and discharging cables
* Cable length: approximately 100–150 mm
Battery documentation:
[https://enerprof.de/en/products/enerpower-4s2p-akku-14-4v-14-8v-10000-mah-li-ion-m50t-mit-kabeln-offenen-enden](https://enerprof.de/en/products/enerpower-4s2p-akku-14-4v-14-8v-10000-mah-li-ion-m50t-mit-kabeln-offenen-enden)
I suggest reserving a battery cavity of at least 91 × 78 × 52 mm, plus 25–30 mm for the cable exit.
The battery should be:
* Positioned low and near the system’s center of gravity
* Replaceable
* Protected from screws and sharp edges
* Retained without concentrated pressure on the cells
* Separated from the processor and power-board heat
* Cushioned using an appropriate flame-retardant material
8. IP2368 power board
The battery is connected to an IP2368 4S 100 W bidirectional USB-C PD module.
Published dimensions for the common module version are:
* PCB: 48 × 34 mm
* Maximum height: approximately 10 mm
* Four M2 mounting holes
* Hole-center spacing: 43.5 × 28.5 mm
* Approximate weight: 20 g
I suggest reserving at least 54 × 40 × 15 mm, with insulating standoffs and airflow around the MOSFETs and inductor.
Several IP2368 PCB layouts exist. I can provide my actual module, photographs and physical measurements before the final CAD is completed.
## 9. External enclosure, controls and connector requirements
The enclosure should have a professional and modern industrial design suitable for recording football matches beside an outdoor field.
Reliability, cooling, mechanical rigidity and accessibility are more important than making the enclosure excessively compact.
### 9.1 Preliminary enclosure dimensions
Based on the current internal components, the preliminary target external envelope is approximately:
* **Width:** 220 mm
* **Height:** 94 mm
* **Depth:** 120 mm
These dimensions are preliminary and may be adjusted after the internal layout study, thermal analysis and confirmation of the minimum practical camera spacing.
The enclosure should maintain rounded external corners, with a suggested corner radius of approximately **8–15 mm**.
The enclosure wall thickness should initially be:
* **2.5–3.0 mm** for a 3D-printed prototype
* Approximately **2.0–2.5 mm** for a future injection-molded version, subject to material and structural analysis
The enclosure must provide enough internal clearance for:
* ROCK 5B+ V1.2 with NVMe SSD
* Radxa Heatsink 6240B V2.0
* Two Radxa Camera 4K modules
* ENERpower 4S2P battery
* IP2368 power-management board
* Internal Wi-Fi, Bluetooth and 5G antennas
* SIM-card extension or accessible SIM-card holder
* HDMI-input connector access
* Wiring, FFC strain relief and service clearances
### 9.2 External control buttons
The enclosure must include two separate external push buttons:
1. **Power button**
2. **Bluetooth button**
The power button will be used to power the device on and off.
It should support:
* Short press for normal power control
* Long press for controlled or safe shutdown
The Bluetooth button will be used for:
* Enabling or disabling Bluetooth
* Starting Bluetooth pairing
* Recovering Bluetooth connectivity without opening the enclosure
The two buttons should be vertically aligned on the side or rear connector panel.
Recommended preliminary button dimensions are:
* **Visible button-cap size:** approximately 14 × 14 mm
* Acceptable button-cap range: **12–16 mm**
* Minimum button travel: approximately **0.5–1.0 mm**
* Minimum spacing between button caps: **6 mm**
* Preferred center-to-center spacing: approximately **20–24 mm**
* Raised protective border: approximately **1.0–1.5 mm**
* Button recess below the surrounding enclosure surface: approximately **0.5–1.0 mm**
Each button should have an engraved, molded or printed symbol:
* Standard power symbol for the power button
* Standard Bluetooth symbol for the Bluetooth button
The symbol should be at least approximately **7–9 mm high** and remain visible in low-light conditions.
The buttons must:
* Provide clear tactile feedback
* Be accessible while the device is mounted on a tripod
* Be protected against accidental activation
* Be suitable for repeated outdoor use
* Use an internal sealing membrane, gasket or sealed actuator
* Be replaceable without replacing the complete enclosure
* Be connected to the main board through removable connectors where practical
The final button cut-out must be based on the selected physical push-button component. Approximately **18 × 42 mm** should initially be reserved internally for the complete two-button control assembly, excluding wiring clearance.
### 9.3 HDMI input
The native HDMI input of the ROCK 5B+ must be accessible from outside the enclosure.
The HDMI opening should correspond to the ROCK 5B+ HDMI-input connector located near the board’s microSD-card area. However, the microSD-card slot itself does not need to be exposed externally.
The exterior panel should display only:
* **HDMI IN**
* **SIM CARD**
* Power button
* Bluetooth button
There should be no external microSD-card opening in this connector panel.
For a standard full-size HDMI Type-A connection, the preliminary enclosure opening should be approximately:
* **Connector opening:** 16 × 7 mm
* **Recommended recessed area:** approximately 24 × 13 mm
* **Minimum clearance around the connector:** 2–3 mm
* **Minimum internal cable-entry depth:** approximately 35 mm
* **Recommended clearance behind the connector:** approximately 40–45 mm where a straight HDMI plug is expected
The exact opening must be verified against the ROCK 5B+ V1.2 STEP model and a real HDMI cable.
The HDMI opening should:
* Allow insertion of common HDMI plugs with moderately thick molded housings
* Avoid mechanical loading of the ROCK 5B+ connector
* Include sufficient finger clearance
* Include cable strain relief or external cable support
* Remain accessible while the device is mounted
* Be clearly marked **HDMI IN**, rather than only HDMI
The mechanical designer should consider a short internal HDMI extension or panel-mount HDMI adapter if direct access to the board connector would place excessive force on the ROCK 5B+ PCB.
### 9.4 External SIM-card access
The SIM card must be removable from outside the enclosure without opening the main electronics compartment.
The preferred arrangement is an externally accessible SIM-card holder or a short SIM-card extension connected to the internal 5G modem.
The exact dimensions depend on whether the final modem uses:
* Nano-SIM
* Micro-SIM
* A push-push SIM holder
* A removable SIM tray
* A flexible SIM extension
For a nano-SIM tray, the preliminary external allocation should be approximately:
* **Visible SIM-tray width:** 14–18 mm
* **Visible SIM-tray height:** 2.5–4 mm
* **Recessed service area:** approximately 24 × 12 mm
* **Minimum finger or tool-access clearance:** 3 mm
* **Minimum spacing from the HDMI recess:** 8–10 mm
Approximately **25 × 20 × 10 mm** should initially be reserved internally for the SIM holder, extension connector and cable bend, subject to the selected component.
The opening must be clearly marked:
**SIM CARD**
The SIM card should not protrude from the enclosure when installed.
A push-push holder, captive tray or protected service door is preferred. The card must not be able to fall inside the enclosure during insertion or removal.
### 9.5 Connector and button-panel arrangement
The preferred arrangement from left to right is:
**HDMI IN — SIM CARD — POWER BUTTON — BLUETOOTH BUTTON**
The two buttons may instead be vertically arranged beside the HDMI and SIM openings when this produces a cleaner and more compact panel.
Recommended preliminary spacing:
* HDMI recess to SIM recess: at least **8–10 mm**
* SIM recess to button-protection area: at least **8 mm**
* Port-panel edge margin: at least **6 mm**
* Distance from external openings to major screw bosses: at least **5 mm**
* Distance from ports to ventilation openings: preferably at least **10 mm**
The connector panel should preferably be positioned on the side or rear of the enclosure so that connected cables do not obstruct:
* Either camera
* The panoramic field of view
* Cooling-air intake
* Warm-air exhaust
* Tripod mounting
* Battery-compartment access
* Camera-angle adjustment
### 9.6 Environmental protection
The HDMI and SIM openings should be protected by one of the following:
* One gasketed and hinged service door
* A removable gasketed connector cover
* Individual attached rubber covers
A single connector door covering both HDMI and SIM access is preferred for a clean commercial appearance.
The preliminary connector-door size should be approximately:
* **Width:** 65–80 mm
* **Height:** 28–35 mm
* **Door thickness:** approximately 2.5–3.0 mm for the prototype
* **Gasket width:** approximately 2–3 mm
The cover should:
* Remain captive when opened
* Include a positive closing mechanism
* Not interfere with the HDMI cable
* Allow replacement of the SIM card
* Protect the openings against dust and light rain
* Avoid placing excessive force on the HDMI connector
* Remain operable without removing the device from the tripod
The device is not initially required to be fully waterproof, but the enclosure should use gasketed construction suitable for outdoor use, dust and light rain.
### 9.7 Additional external requirements
The enclosure must also include:
* One accessible USB-C charging and power connection
* One accessible USB 3.0 connection
* External power, battery and recording indicators
* Recessed recovery or reset access
* Replaceable protective camera windows
* Threaded metal inserts
* Internal antennas with no externally protruding Wi-Fi or cellular antennas
* A 1/4-20 UNC metal tripod insert positioned near the complete system’s center of gravity
* Optional anti-rotation mounting points
* A removable battery compartment or battery-access panel
* A service cover for maintenance connectors that are not required during normal operation
The camera calibration must remain unchanged when opening the battery or electronics compartments.
The complete dual-camera mounting assembly should be removable as one rigid and calibrated unit.
The first prototype may be 3D printed, but the design should consider future:
* Low-volume CNC machining
* Urethane casting
* Vacuum casting
* Injection molding
All dimensions relating to connector cut-outs, push buttons, SIM holders and panel-mount extensions must be checked against the selected real components before the final STEP and STL files are released.
10. Requested phased quotation
To control the initial development cost, I would appreciate separate quotations for two phases.
Phase 1 – Mechanical architecture and concept
* Review of the supplied STEP models and physical hardware
* Internal component-layout study
* Minimum-parallax camera arrangement
* Adjustable 49–62° camera-mount concept
* Cooling and battery-placement concept
* Preliminary enclosure design
* Initial STEP assembly
* One or two design-review iterations
Phase 2 – Detailed design and prototype
* Final production-quality CAD
* Detailed camera adjustment and locking mechanism
* STEP and print-ready STL files
* 2D manufacturing drawings
* Fastener and purchased-component BOM
* Exploded assembly drawing
* Prototype fabrication support
* Design-for-manufacturing review
Please provide the estimated schedule and fixed-price or budget range for each phase separately.
Please let me know whether this project fits your mechanical and industrial-design capabilities and what additional information you require to prepare a quotation.
Best regards,
Mohamed Jâafar
France read less
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