Initial design: ESP32-S3 presence sensor with camera, mmWave, PIR, temp/humidity, light

- KiCad schematic and PCB layout (45x35mm board)
- Full BOM with JLCPCB part numbers
- ESPHome firmware configuration
- 3D-printable wall-mount enclosure (OpenSCAD + STL)
- Pin mapping and power budget documentation

enclosure/body_only.scad

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+include <enclosure.scad>;
+// Only body is rendered (default render includes both)

enclosure/enclosure.scad

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+// ============================================
+// Presence Sensor Wall-Mount Enclosure
+// ESP32-S3 + OV5640 + LD2410C + AM312 + SHT41 + BH1750
+// Board: 45 x 35 mm
+// ============================================
+
+// Dimensions (mm)
+pcb_w = 45;          // PCB width
+pcb_h = 35;          // PCB height
+pcb_t = 1.6;         // PCB thickness
+
+wall = 1.8;          // Wall thickness
+tolerance = 0.3;     // Fit tolerance
+bottom_gap = 3;      // Space below PCB for solder joints
+top_gap = 12;        // Space above PCB for components + modules
+lid_lip = 1.5;       // Lid overlap lip
+
+// Derived
+inner_w = pcb_w + tolerance * 2;
+inner_h = pcb_h + tolerance * 2;
+inner_d = bottom_gap + pcb_t + top_gap;
+outer_w = inner_w + wall * 2;
+outer_h = inner_h + wall * 2;
+outer_d = inner_d + wall;  // Open top (lid covers)
+
+// Screw post dimensions
+post_d = 4.5;        // Post outer diameter
+screw_d = 2.2;       // M2 screw hole
+post_h = bottom_gap;  // Height to PCB level
+
+// Component positions (from bottom-left of PCB)
+cam_x = pcb_w / 2;          // Camera centered horizontally
+cam_y = pcb_h - 5;          // Camera near top
+cam_hole_w = 10;             // Camera lens window
+cam_hole_h = 10;
+
+pir_x = 12;                 // PIR left of center
+pir_y = pcb_h - 20;
+pir_hole_d = 10;             // AM312 dome diameter
+
+light_x = 30;               // BH1750 right of center
+light_y = pcb_h - 20;
+light_hole_d = 4;            // Small window for light sensor
+
+mmwave_x = pcb_w / 2;       // LD2410C centered
+mmwave_y = 8;                // Near bottom
+mmwave_slot_w = 8;           // Slot for radar signal
+mmwave_slot_h = 36;
+
+usbc_x = pcb_w / 2;         // USB-C centered bottom
+usbc_w = 10;
+usbc_h = 4;
+
+vent_slot_w = 1.5;
+vent_slot_h = 8;
+
+// ============================================
+// Main body
+// ============================================
+module body() {
+    difference() {
+        // Outer shell
+        rounded_box(outer_w, outer_h, outer_d, 3);
+
+        // Inner cavity
+        translate([wall, wall, wall])
+            rounded_box(inner_w, inner_h, inner_d + 1, 2);
+
+        // Camera window (front face - top)
+        translate([wall + tolerance + cam_x - cam_hole_w/2,
+                   wall + tolerance + cam_y - cam_hole_h/2,
+                   -1])
+            rounded_box(cam_hole_w, cam_hole_h, wall + 2, 2);
+
+        // PIR window (front face)
+        translate([wall + tolerance + pir_x,
+                   wall + tolerance + pir_y,
+                   -1])
+            cylinder(h=wall+2, d=pir_hole_d, $fn=32);
+
+        // Light sensor window (front face)
+        translate([wall + tolerance + light_x,
+                   wall + tolerance + light_y,
+                   -1])
+            cylinder(h=wall+2, d=light_hole_d, $fn=32);
+
+        // USB-C cutout (bottom edge)
+        translate([wall + tolerance + usbc_x - usbc_w/2,
+                   -1,
+                   wall + bottom_gap - 1])
+            cube([usbc_w, wall + 2, usbc_h + 2]);
+
+        // Ventilation slots (sides - for SHT41 airflow)
+        for (i = [0:3]) {
+            // Left side
+            translate([-1,
+                       wall + 5 + i * (vent_slot_h + 2),
+                       wall + bottom_gap + pcb_t + 2])
+                cube([wall + 2, vent_slot_h, vent_slot_w]);
+            // Right side
+            translate([outer_w - wall - 1,
+                       wall + 5 + i * (vent_slot_h + 2),
+                       wall + bottom_gap + pcb_t + 2])
+                cube([wall + 2, vent_slot_h, vent_slot_w]);
+        }
+
+        // mmWave radar slot (through back wall for better signal)
+        translate([wall + tolerance + mmwave_x - mmwave_slot_w/2,
+                   wall + tolerance + mmwave_y - mmwave_slot_h/2,
+                   outer_d - wall - 0.5])
+            rounded_box(mmwave_slot_w, mmwave_slot_h, wall + 1, 1);
+
+        // Wall mount screw slots (keyhole on back)
+        translate([outer_w/2, outer_h * 0.3, outer_d - wall - 1])
+            wall_mount_keyhole();
+        translate([outer_w/2, outer_h * 0.7, outer_d - wall - 1])
+            wall_mount_keyhole();
+    }
+
+    // PCB support posts
+    for (pos = [[wall + tolerance + 2.5, wall + tolerance + 2.5],
+                [wall + tolerance + pcb_w - 2.5, wall + tolerance + 2.5],
+                [wall + tolerance + 2.5, wall + tolerance + pcb_h - 2.5],
+                [wall + tolerance + pcb_w - 2.5, wall + tolerance + pcb_h - 2.5]]) {
+        translate([pos[0], pos[1], wall])
+            difference() {
+                cylinder(h=post_h, d=post_d, $fn=20);
+                cylinder(h=post_h + 1, d=screw_d, $fn=20);
+            }
+    }
+}
+
+// ============================================
+// Lid (snap-fit)
+// ============================================
+module lid() {
+    difference() {
+        union() {
+            // Lid plate
+            rounded_box(outer_w, outer_h, wall, 3);
+
+            // Inner lip for alignment
+            translate([wall - lid_lip/2, wall - lid_lip/2, wall])
+                rounded_box(inner_w + lid_lip, inner_h + lid_lip, 2, 2);
+        }
+
+        // Status LED window (small hole)
+        translate([wall + tolerance + 40, wall + tolerance + 25, -1])
+            cylinder(h=wall+2, d=2, $fn=16);
+    }
+}
+
+// ============================================
+// Helper modules
+// ============================================
+module rounded_box(w, h, d, r) {
+    hull() {
+        translate([r, r, 0]) cylinder(h=d, r=r, $fn=20);
+        translate([w-r, r, 0]) cylinder(h=d, r=r, $fn=20);
+        translate([r, h-r, 0]) cylinder(h=d, r=r, $fn=20);
+        translate([w-r, h-r, 0]) cylinder(h=d, r=r, $fn=20);
+    }
+}
+
+module wall_mount_keyhole() {
+    // Large hole (screw head)
+    cylinder(h=wall+2, d=7, $fn=24);
+    // Slot (slide down to lock)
+    translate([0, -5, 0])
+        hull() {
+            cylinder(h=wall+2, d=4, $fn=24);
+            translate([0, 5, 0]) cylinder(h=wall+2, d=4, $fn=24);
+        }
+}
+
+// ============================================
+// Render
+// ============================================
+
+// Body
+body();
+
+// Lid (offset for viewing - move to origin for printing)
+translate([outer_w + 10, 0, 0])
+    lid();

enclosure/lid_only.scad

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+use <enclosure.scad>;
+lid();