# From model proposal to compiled CAD

This crosswalk was authored after the model review and CAD compilation. The model proposal IDs and the CAD instance IDs are separate namespaces. Mapping a part does not mean that the model approved its later construction details.

Sources: [actual orchestrator review](review-notes.md), [mechanical contract](mechanical-design.json), [compiled inventory](parts.json), [CAD implementation and checks](cad-manifest.json), [machine-readable crosswalk and bound checks](design-to-cad-map.json).

The inventory contains 85 component instances and 8 fastener envelopes, with 46 distinct non-fastener designs and 10 functional subassemblies. These physical groups sit inside the three LIGHT planning modules.

## Part crosswalk

| Model proposal | Meaning | CAD design ID | Actual CAD instances |
| --- | --- | --- | --- |
| P01 | Base | `station-base` | `W01` |
| P02 | Y rail | `y-guide-rail` | `W04_0`, `W04_1` |
| P03 | Y carriage | `y-carriage` | `W05_0_0`, `W05_0_1`, `W05_1_0`, `W05_1_1` |
| P04 | Y saddle | `y-saddle` | `W06_0`, `W06_1` |
| P05 | Gantry tower | `gantry-tower` | `W07_0`, `W07_1` |
| P06 | Bridge | `gantry-bridge` | `W09` |
| P07 | X rail | `x-guide-rail` | `W10` |
| P08 | X carriage | `x-carriage` | `W11` |
| P09 | X screw | `x-lead-screw` | `W12` |
| P10 | Focus backplate | `focus-backplate` | `W18` |
| P11 | Focus rod | `focus-guide-rod` | `W19_0`, `W19_1` |
| P12 | Focus screw | `focus-lead-screw` | `W23` |
| P13 | Camera-body envelope | `camera-envelope` | `W26` |
| P14 | Lens envelope | `lens-barrel` | `W27` |
| P15 | Ring-light envelope | `ring-light` | `W28` |
| P16 | Deck | `perforated-deck` | `W31` |
| P17 | Standoff | `deck-spacer` | `W32_0`, `W32_1`, `W32_2`, `W32_3` |
| P18 | Rear panel | `rear-panel` | `W42` |
| P19 | Side panel | `side-screen` | `W43_0`, `W43_1` |
| P20 | Controller housing | `controller-shell` | `W37` |
| P21 | Controller lid | `controller-lid` | `W38` |
| P22 | Carrier link | `carrier-link` | `W45_01`, `W45_02`, `W45_03`, `W45_04`, `W45_05`, `W45_06`, `W45_07`, `W45_08`, `W45_09`, `W45_10`, `W45_11`, `W45_12` |
| P23 | Foot | `station-foot` | `W02_1`, `W02_2`, `W02_3`, `W02_4` |

P01–P23 and SA01–SA10 come from the [actual mechanical worker findings](calls/worker-a.txt), explicitly accepted by the final orchestrator.

## Functional groups

| Model group | Meaning | Actual CAD group |
| --- | --- | --- |
| SA01 | Base and feet | `01_base` |
| SA02 | Y guidance/carriages | `02_y_axis` |
| SA03 | Gantry | `03_gantry` |
| SA04 | X guidance/carriage/screw | `04_x_axis` |
| SA05 | Z guidance/screw | `05_focus` |
| SA06 | Optics envelopes | `06_optics` |
| SA07 | Deck/workholding | `07_workholding` |
| SA08 | Enclosure | `09_enclosure` |
| SA09 | Controller housing | `08_controller` |
| SA10 | Cable carrier | `10_cable_carrier` |

## Additional authored geometry

These designs were supplied by the later CAD author. They do not receive a fabricated P identifier or retrospective model approval. The original proposed BOM remains unchanged.

| CAD design | Meaning | Actual instances | Group |
| --- | --- | --- | --- |
| `y-riser` | Rail support riser | `W03_0`, `W03_1` | `02_y_axis` |
| `gantry-gusset` | Triangular saddle gusset | `W08_0_0`, `W08_0_1`, `W08_1_0`, `W08_1_1` | `03_gantry` |
| `x-bearing-support` | X shaft bearing support | `W13_0`, `W13_1` | `04_x_axis` |
| `x-motor-envelope` | X motor nominal envelope | `W14` | `04_x_axis` |
| `x-motor-mount` | X motor L mount | `W15` | `04_x_axis` |
| `x-coupler` | X flexible coupling envelope | `W16` | `04_x_axis` |
| `x-lead-nut` | X lead nut | `W17` | `04_x_axis` |
| `focus-end-block` | Focus shaft end block | `W20_0`, `W20_1` | `05_focus` |
| `focus-slider` | Focus carriage plate | `W21` | `05_focus` |
| `focus-bushing` | Focus linear bushing | `W22_0`, `W22_1` | `05_focus` |
| `focus-motor-envelope` | Focus motor nominal envelope | `W24` | `05_focus` |
| `camera-mount` | Camera angle mounting bracket | `W25` | `06_optics` |
| `lens-window` | Optical window envelope | `W29` | `06_optics` |
| `ring-bracket` | Illuminator support bracket | `W30` | `06_optics` |
| `locating-pin` | Locating pin | `W33_0`, `W33_1` | `07_workholding` |
| `hold-down-clamp` | Slotted hold-down clamp | `W34_0`, `W34_1` | `07_workholding` |
| `clamp-hand-screw` | Clamp hand screw envelope | `W35_0`, `W35_1` | `07_workholding` |
| `calibration-coupon` | Perforated calibration coupon; uncalibrated | `W36` | `07_workholding` |
| `switch-envelope` | Manual switch envelope; not wired | `W39` | `08_controller` |
| `panel-connector` | Panel connector envelope | `W40_0`, `W40_1` | `08_controller` |
| `cable-gland` | Cable gland envelope | `W41_0`, `W41_1` | `08_controller` |
| `rear-post` | Rear panel post | `W44_0`, `W44_1` | `09_enclosure` |
| `carrier-end-bracket` | Cable carrier end bracket | `W46_0`, `W46_1` | `10_cable_carrier` |
| `M6x12-envelope` | Nominal M6 mounting screw envelope | `B01_1`, `B01_2`, `B01_3`, `B01_4`, `B01_5`, `B01_6`, `B01_7`, `B01_8` | `11_fasteners` |

## Proposed record and image references

- `FX-DECK-GRID-r1` maps to P16 / `W31`, the deck grid. Later locating pins, clamps and coupon are distinct author additions; the reference does not establish tested workholding.
- `IMG-ASM` can now resolve to [assembled.svg](assembled.svg), and `IMG-EXP` to [exploded.svg](exploded.svg). These are renderings of the compiled geometry.
- `IMG-SEC` remains unresolved: the [engineering drawing](engineering-drawing.svg) provides orthographic views, not a claimed section cut or motion study.
- `M-SETUP-r1` is still a proposed application manifest. This crosswalk does not create a deployed staff application, an inspected sample or an acknowledged handoff.

## Implementation decisions and limits

- Builder-authored focus-backplate relief: removed X244..296, Y123..133, Z163..235 mm from the locked plate envelope to clear the centered camera and ring light. The original outer plate dimensions and optical axis are unchanged. This relief was not approved by the model review.
- Builder-authored integral mounting bosses bridge the 8 mm gap from focus backplate to X carriage at X239..253 and X287..301, Y132..140, Z310..330 mm. Joint fastening and strength are unresolved.
- Builder-authored radius9.2 mm seat in the X carriage gives the nominal radius9 mm lead nut clearance; retention and screw alignment are unvalidated.
- Builder-authored camera bracket ends at Y124 mm and its neck at Z246 mm, meeting the backplate/carriage without positive-volume overlap. Guide-rod and screw passages are cut through its shelf. The lower guide block has a radius13 mm lens aperture, and the illuminator bracket a radius4.2 mm guide passage. These clearances do not establish fastening, stiffness or retention.
- Builder-authored clamp slots and diameter4.6 mm screw envelopes align to existing grid holes at (210,120) and (310,120); clamp faces touch the coupon at Z66 mm. Threads, axial retention and clamping force are undefined.
- Detailed holes, hollow sections, nominal motor/connector shapes, cable links and workholding hardware implement the concept for inspection; they do not represent qualified commercial parts.

Unresolved in the CAD author’s own manifest:

- KNOWN STATIC INTERFERENCE: the reviewed focus-screw axis passes through the reviewed camera envelope (W23/W26). The exact positive overlap is recorded as a failed digital check; the reviewed placements are deliberately retained. A revised mechanical layout and model review are required to resolve this.
- No validated fastener/retention scheme for the focus bosses, X nut, optics, rails or cable carrier.
- No swept-motion collision analysis; limits and cable flex have not been established.
- The side/rear screens are visual concept panels and do not establish guarding or safe energized operation.
- The CAD implementation decisions resolve selected static geometric clashes only; they do not constitute an approved engineering resolution of all model-review findings.

## Reported CAD conflicts

The supplied dimensions can agree with the inventory while parts still overlap. The CAD builder reports these failed selected geometry checks; their conflicts remain unresolved in this saved concept.

| Failed check | Parts | Reported geometric result |
| --- | --- | --- |
| Focus lead screw intersects locked camera envelope | `W23`, `W26` | `{"intersectionVolumeMm3":1130.97335529,"maximumMm3":0.001}` |

Feet extend below the base-origin plane as an explicit authored placement. The model-reviewed outer dimensions remain traceable; added features and extra designs are identified separately.

Independent inventory comparison: **85 selected bounds, positions and counts agree** within 0.0001 mm numeric tolerance. This checks the compiled inventory against the supplied values; it does not repeat the CAD kernel or prove that every interface, bore, wall, stroke or attachment is correct.

For the workstation, the original focus plate is 8 mm thick; its integrated 8 mm bosses make the finished part bounding depth 16 mm. The audit explicitly accounts for this authored addition instead of claiming that the whole finished part still has an 8 mm depth.