FreeCAD – Part 10: Tablet Face Enclosure

In this lesson, we design the tablet face enclosure of the Millie Mini AI robot, creating the structural housing that securely holds the tablet and defines the robot’s front-facing interface.

This lesson focuses on building a precision-fit enclosure that integrates cleanly with the neck shaft while maintaining the robot’s modular design language.

Designing the Outer Enclosure

We begin by modeling the outer geometry of the tablet housing.

This lesson demonstrates how engineers create electronic enclosures that balance structural integrity and visual clarity.

The goal here is to define a clean exterior form that frames the robot’s display.

Defining the Display Opening

Next, we create the front-facing opening that frames the tablet screen.

In this lesson, we:

Define the front cutout geometry
Ensure accurate screen proportions
Maintain even border spacing
Preserve symmetry and alignment

This establishes the visual identity of the robot’s face.

Creating Internal Support Structure

With the outer shell defined, we design the internal supports that secure the tablet in place.

In this lesson, we:

Add interior support geometry
Adjust clearances for proper fit
Confirm stable mounting surfaces
Maintain structural consistency

This ensures the tablet will sit securely within the enclosure.

Aligning with the Neck Shaft

Once the enclosure is complete, we integrate it with the neck assembly.

In this lesson, we:

Center the enclosure on the neck shaft
Confirm clean transitions between components
Verify proportional balance
Lock in mounting orientation

The robot’s head housing is now structurally defined.

Result So Far

By the end of this lesson, you will have:

Designed the tablet enclosure
Defined the front display opening
Created internal support geometry
Integrated the enclosure with the neck
Established the robot’s face housing

At this stage, the Millie Mini AI robot now has a defined head structure ready for final connection detailing.

What’s Next

In the next lesson, we’ll design the face plate and neck joint.

We’ll:

Create the structural face plate
Design the neck connection interface
Refine mounting geometry
Finalize the head-to-neck integration

This is where the head assembly becomes mechanically unified with the robot’s core structure.