[family] minifix_cam_housing: Häfele Minifix 15 connector housing

designs/minifix_cam_housing/NOTES.md

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+# Minifix 15 geometry notes
+
+## Evidence scope
+
+The seven installation rows come from Häfele UK catalogues `14CFC294.pdf`
+and `14CFC295.pdf`, pp. 294--295. The reference item is Häfele
+**262.25.035**, `Cas. Minifix 15R/19`, downloaded as STEP AP214 from the
+[Häfele Minifix 15 product page](https://www.hafele.com/us/en/product/connector-housing-minifix-15/P-00861332/)
+on 2026-07-23.
+
+The STEP has two transfer roots. Root 1 is a 27-face CADClick artefact with
+zero volume. Root 2 is the actual 342-face manufacturer solid. Root 2 is used
+only for local measurement and visual comparison; it is not imported by
+`build()` and no OEM BREP, STEP, or encoded topology is part of this family.
+
+## Baseline measurements
+
+| Landmark | OEM root 2 | Catalogue nominal |
+|---|---:|---:|
+| Bounding box | 16.30 x 16.30 x 14.65 mm | -- |
+| Housing bore | 14.90 mm casting OD | 15 mm drill hole |
+| Rim diameter | 16.30 mm | 16.5 mm |
+| Rim projection | 0.80 mm | 1.0 mm |
+| Casting end | 13.85 mm from installation plane | X = 14.5 mm |
+| Bolt-axis datum | 9.50 mm | A = 9.5 mm |
+| OEM solid volume | 801.707894 mm3 | -- |
+
+## Reconstruction approach
+
+The model is rebuilt from named CadQuery features, in the visible OEM order:
+
+1. shallow operating disc, drive recess, and curved direction arrow;
+2. offset eccentric capture cam with a bolt-entry slot;
+3. two independent open C-plates rather than a solid circular floor;
+4. asymmetric legs, short upper ears, and a partial rear shell that leave the
+   major OEM windows open.
+
+The exact catalogue rows drive bore diameter, rim choice, `A`, `X`, and the
+7/8 mm bolt-hole choice. The internal cam length, plate mouths, support-leg
+placement, and rear-shell thickness are **proportion** fits to the one OEM
+baseline because the catalogue does not dimension those casting features and
+does not supply CAD for the other six rows.
+
+## Verification of the 19 mm baseline
+
+| Metric | OEM root 2 | Parametric reconstruction | Difference |
+|---|---:|---:|---:|
+| Bounding box X | 16.300000 mm | 16.300000 mm | < 0.000001 mm |
+| Bounding box Y | 16.300000 mm | 16.300000 mm | < 0.000001 mm |
+| Bounding box Z | 14.650000 mm | 14.650000 mm | < 0.000001 mm |
+| Solid count | 1 | 1 | 0 |
+| Face count | 342 | 88 | readable analytic reconstruction |
+| Volume | 801.707894 mm3 | 814.091087 mm3 | +1.54% |
+
+## Deliberate deviations
+
+- The CAD source has no recoverable feature tree. This is a new parametric
+  reconstruction, not copied manufacturer topology.
+- OEM local blends, drafts, and small windows are simplified where their
+  dimensions are not published.
+- Only item 262.25.035 directly anchors the internal casting. Cross-SKU
+  internal changes are proportional, not asserted manufacturer dimensions.
+- The family is not production, tolerance, or fit data.

designs/minifix_cam_housing/family.json

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+{
+  "family": "minifix_cam_housing",
+  "standard": null,
+  "base_plane": "XY",
+  "description": "Häfele Minifix 15 die-cast eccentric-cam connector housing with an open cage, optional seating rim, combination PZ2/flat/SW4 drive, and radial bolt-capture mouth.",
+  "source": "Häfele UK catalogue 14CFC294.pdf and 14CFC295.pdf, pp. 294--295, supplies seven nominal installation rows; Häfele US P-00861332 item 262.25.035 STEP AP214 anchors the 19 mm baseline through 27 sampled horizontal sections and measured landmarks; cross-SKU transforms remain proportion.",
+  "contributor": "snowy-void"
+}

designs/minifix_cam_housing/part.py

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+"""Parametric reconstruction of the Häfele Minifix 15 eccentric cam housing.
+
+The construction deliberately follows the OEM's visible feature hierarchy:
+operating disc, eccentric capture cam, two open C-plates, and asymmetric
+support legs.  It does not reuse the earlier whole-body section loft.
+"""
+
+import math
+
+import cadquery as cq
+
+
+def _annular_sector(outer_radius, inner_radius, z0, z1, center, half_angle):
+    """Return one open, circular casting sector between two Z stations."""
+
+    def wire(z):
+        outer = cq.Edge.makeCircle(
+            outer_radius,
+            (0.0, 0.0, z),
+            (0.0, 0.0, 1.0),
+            center - half_angle,
+            center + half_angle,
+            True,
+        )
+        inner = cq.Edge.makeCircle(
+            inner_radius,
+            (0.0, 0.0, z),
+            (0.0, 0.0, 1.0),
+            center - half_angle,
+            center + half_angle,
+            False,
+        )
+        return cq.Wire.assembleEdges(
+            [
+                outer,
+                cq.Edge.makeLine(outer.endPoint(), inner.startPoint()),
+                inner,
+                cq.Edge.makeLine(inner.endPoint(), outer.startPoint()),
+            ]
+        )
+
+    return cq.Solid.makeLoft([wire(z0), wire(z1)], ruled=True)
+
+
+def _c_plate(radius, thickness, z0, mouth_center, mouth_width):
+    """Cut a broad radial mouth from a round terminal casting plate."""
+    plate = cq.Workplane("XY").workplane(offset=z0).circle(radius).extrude(thickness)
+    plate = plate.edges("%CIRCLE").fillet(min(0.22, thickness * 0.30))
+    cutter = (
+        cq.Workplane("XY")
+        .workplane(offset=z0 - 0.08)
+        .center(mouth_center, 0.0)
+        .rect(mouth_width, radius * 1.36)
+        .extrude(thickness + 0.16)
+    )
+    return plate.cut(cutter)
+
+
+def _drive_cutter(scale, z0):
+    """Make the measured PZ/flat/hex combination drive recess."""
+    horizontal = (
+        cq.Workplane("XY")
+        .workplane(offset=z0)
+        .rect(6.80 * scale, 1.62 * scale)
+        .extrude(2.15 * scale)
+    )
+    vertical = (
+        cq.Workplane("XY")
+        .workplane(offset=z0)
+        .rect(1.62 * scale, 6.80 * scale)
+        .extrude(2.15 * scale)
+    )
+    pz = horizontal.union(vertical)
+    hex_radius = 2.32 * scale
+    hex_points = [
+        (
+            hex_radius * math.cos(math.radians(30.0 + 60.0 * index)),
+            hex_radius * math.sin(math.radians(30.0 + 60.0 * index)),
+        )
+        for index in range(6)
+    ]
+    socket = (
+        cq.Workplane("XY")
+        .workplane(offset=z0 + 1.85 * scale)
+        .polyline(hex_points)
+        .close()
+        .extrude(1.85 * scale)
+    )
+    return pz.union(socket)
+
+
+def _arrow_cutter(radius, width, z0, depth, center):
+    """Make a curved recessed operating-direction arrow."""
+    half_angle = 47.0
+    band = _annular_sector(radius, radius - width, z0, z0 + depth, center, half_angle)
+    angle = math.radians(center + half_angle)
+    radial = (math.cos(angle), math.sin(angle))
+    tangent = (-radial[1], radial[0])
+    middle = radius - width / 2.0
+    x, y = middle * radial[0], middle * radial[1]
+    head = (
+        cq.Workplane("XY")
+        .workplane(offset=z0)
+        .polyline(
+            [
+                (x + radial[0] * width, y + radial[1] * width),
+                (x - radial[0] * width, y - radial[1] * width),
+                (x + tangent[0] * width * 2.0, y + tangent[1] * width * 2.0),
+            ]
+        )
+        .close()
+        .extrude(depth)
+    )
+    return band.fuse(head.val())
+
+
+def _support_leg(x, y, width, depth, height, z0):
+    """Return a rounded vertical die-cast support that joins both plates."""
+    leg = cq.Workplane("XY").workplane(offset=z0).center(x, y).rect(width, depth).extrude(height)
+    try:
+        return leg.edges("|Z").fillet(min(width, depth) * 0.16)
+    except ValueError:
+        return leg
+
+
+def build(
+    body_diameter,
+    housing_height,
+    has_rim,
+    rim_diameter,
+    rim_height,
+    bolt_axis_height,
+    bolt_hole_diameter,
+):
+    """Build the Minifix casting around the catalogue bore, A, and X data."""
+    scale = body_diameter / 15.0
+    body_radius = (body_diameter - 0.10) / 2.0
+    body_depth = housing_height - 0.65
+    face_radius = (rim_diameter - 0.20) / 2.0 if has_rim else body_radius
+    face_thickness = 0.80 * rim_height if has_rim else 0.48 * scale
+    lower_plate_thickness = 0.74 * scale
+    lower_plate_z = body_depth - lower_plate_thickness
+    mid_plate_z = max(3.05 * scale, bolt_axis_height - 0.85 * scale)
+
+    # Operating disc: the OEM rim is a shallow, broad circular casting above
+    # the installation plane; the recesses are cut before final orientation.
+    face = (
+        cq.Workplane("XY")
+        .workplane(offset=-face_thickness)
+        .circle(face_radius)
+        .extrude(face_thickness)
+    )
+    face = face.edges("%CIRCLE").fillet(min(0.20 * scale, face_thickness * 0.28))
+    face = face.cut(_drive_cutter(scale, -face_thickness - 0.03 * scale))
+    arrow_radius = min(face_radius - 0.58 * scale, 6.35 * scale)
+    arrow = _arrow_cutter(arrow_radius, 0.48 * scale, -face_thickness - 0.02, 0.22 * scale, 78.0)
+    face = face.cut(arrow)
+
+    # The central member is an offset eccentric barrel.  Its round capture
+    # pocket opens toward the connecting bolt instead of filling the housing.
+    cam_radius = 4.42 * scale
+    cam_x, cam_y = 0.42 * scale, 1.98 * scale
+    cam_z0 = -0.04
+    cam_z1 = min(lower_plate_z + 0.10, mid_plate_z - 2.80 * scale)
+    cam = (
+        cq.Workplane("XY")
+        .workplane(offset=cam_z0)
+        .center(cam_x, cam_y)
+        .circle(cam_radius)
+        .extrude(cam_z1 - cam_z0)
+    )
+    clearance = 1.0 + 0.18 * (bolt_hole_diameter - 7.0)
+    capture = (
+        cq.Workplane("XZ")
+        .center(-2.10 * scale, bolt_axis_height)
+        .slot2D(4.00 * scale * clearance, 3.55 * scale * clearance, 90.0)
+        .extrude(body_diameter, both=True)
+    )
+    cam = cam.cut(capture)
+
+    # The lower end is the defining open C-plate, not a full circular floor.
+    lower_plate = _c_plate(
+        body_radius,
+        lower_plate_thickness,
+        lower_plate_z,
+        -body_radius + 4.00 * scale,
+        8.10 * scale,
+    )
+    mid_plate = _c_plate(
+        6.45 * scale,
+        0.64 * scale,
+        mid_plate_z,
+        -6.45 * scale + 3.15 * scale,
+        bolt_hole_diameter * 0.95 * scale,
+    )
+
+    # Two broad asymmetric legs and a rear curved shell reproduce the large
+    # open windows visible in the OEM views, rather than a cylindrical cage.
+    leg_height = body_depth + 0.04
+    left_leg = _support_leg(
+        -5.52 * scale, 0.30 * scale, 1.34 * scale, 2.12 * scale, leg_height, -0.04
+    )
+    right_leg = _support_leg(
+        3.95 * scale, -1.65 * scale, 1.58 * scale, 2.04 * scale, leg_height, -0.04
+    )
+    rear_shell = _annular_sector(
+        body_radius,
+        body_radius - 1.36 * scale,
+        -0.04,
+        body_depth,
+        180.0,
+        23.0,
+    )
+    rear_shell = cq.Workplane("XY").newObject([rear_shell]).cut(capture)
+
+    # Short upper ears carry the rectangular OEM windows below the operating
+    # disc while keeping the large central opening visible.
+    ear_height = min(3.25 * scale, lower_plate_z * 0.42)
+    left_ear = _support_leg(
+        -4.75 * scale, 3.80 * scale, 1.20 * scale, 1.56 * scale, ear_height, -0.04
+    )
+    right_ear = _support_leg(
+        4.82 * scale, 3.58 * scale, 1.20 * scale, 1.56 * scale, ear_height, -0.04
+    )
+
+    result = face.union(cam).union(lower_plate).union(mid_plate)
+    result = result.union(left_leg).union(right_leg).union(rear_shell)
+    result = result.union(left_ear).union(right_ear)
+    result = result.rotate((0.0, 0.0, 0.0), (1.0, 0.0, 0.0), 180.0)
+    return result.clean()