EMFCamp Tildagon Hexpansion Base - Robust Screw Mount

This is not useful in and of itself, it may just be useful to build something else that mounts on an EMFCamp Tildagon badge as a hexpansion.

I wanted a hexpansion that can resist a fair bit of force applied to it, so designed a base that's thickened out to 1.8mm down to the mounting screw holes. This is just about / maybe within the specification for hexpansions. There is a second version that has a pair of “prongs” for rigidity, this version does not conform to the specification as it goes over 1mm where it shouldn't, however in practical reality there is nothing on any hexpansion port that interferes with this (it does not contact the battery).

Designed this for the KatArm Hexpansion - decided it was worth publishing separately. (This is why there is also a holy version.)

I've also attached the DXF and FreeCAD files with the basic components, useful for doing your own thing with these - they could be made thicker for even more robustness for example, there is definitely more clearance available.

The base dimensions for the hexpansion are taken from here: https://github.com/emfcamp/badge-2024-hardware/tree/main/hexpansion

I assert no ownership of this design and include a copy of the “CERN Open Hardware Licence Version 2 - Permissive” provided with that project.

I used the basic hexpansion outline and made a 3D model of it with reinforced upper section.