I’ve been working on making the PCB layout and enclosure match the appearance I wanted for HandiNAVI.

I started laying out the screen and buttons in FreeCAD (I know the hackpad guide recommends Fusion360, but I recently switched to Linux and I don’t think it’s available on my system; it’s a pain to use anyway), using constrained sketches to set their sizes and positions. Midway through I realised I didn’t like where I’d placed the switches, so I had to go back and edit the PCB. I moved the switches higher in KiCad, bringing the buttons closer to the screen. I also had to reposition the LCD because the “F.Courtyard” layer was overlapping with one of the switches.

Moving the components meant repairing the routing. I reconnected SW1–SW4, adjusted the LCD signal and power tracks, and refilled the ground zones. The updated DRC report showed no unconnected pads, with one remaining silkscreen warning that I addressed by moving the SW3 label. I then exported the updated STEP model and resumed work in FreeCAD.

I also imported the Waveshare 1.8-inch LCD model and positioned it above the PCB. Using its actual geometry helped me size and align the screen opening.

The case now has a 2 mm front plate, four button openings, 2 mm sidewalls, and a USB opening aligned with the XIAO’s connector. I made a separate back cover with four PCB support posts and pilot holes, then added posts to the front shell and matching clearance holes through the back cover so the two halves can be screwed together.

The current CAD check found valid case solids, aligned mounting holes, and no intersections between the case and the imported electronics. The assembled enclosure is currently 71 × 106 × 22 mm.

Now I think my next objective is probably to add the LCD mounting posts, and round the case/make it prettier. I should probably double check this with someone else but I’ll get around to it (maybe :p)