# Xeon layered skull — process notes

Documented September 13, 2026.

Onshape: https://cad.onshape.com/documents/96aebf30b72ce6df1badf456/w/f91b9825c8a19c3fe01f44b3/e/e7915f1da83ac3bb37acfd75

## Current configuration

- Skull-height input: 12 in (304.8 mm), excluding the base and stand-off.
- Plate stock: 0.100 in (2.54 mm); CAD material property: mild steel.
- Minimum plate gap input: 0.030 in (0.762 mm).
- Slot clearance: 0.006 in (0.1524 mm) total added width and length.
- 73 skull plates, one base, 146 base slots.
- Calculated plate pitch: 3.3838167 mm. Actual clear gap: 0.8438167 mm.
- Calculated slot width: 2.6924 mm; slot length at this scale: 16.1524 mm.

## Construction logic

1. Select the shape scale and stock thickness in the Layered skull feature.
2. Calculate an odd plate count from the available width, stock, and minimum gap. The saved rule bounds the count to 5–81.
3. Select profiles from the saved symmetric bank, draw closed loops, and extrude each plate to stock thickness.
4. Alternate the paired tab patterns. Generate base slots from those same plate positions and tab centers.
5. Use Layout for cutting to place all parts in a spaced six-column grid. This is not a production nest or machine program.
6. Verify the selected configuration before exporting. A saved DXF filename in the document identifies a 6-inch version; this article documents the current 12-inch model.

## Before a physical build

Measure stock; cut a fit coupon; review thin bridges and edge conditions; establish plate order and retention; verify handling stability; check export units, scale, revision, and all part identifiers.

## Documentation method

The article follows the saved FeatureScript and current CAD configuration, not a time-stamped reconstruction of the original modeling session. Onshape views were captured directly. Component visibility and cutting-layout preview were used to explain the geometry; the assembled state was restored.

## Credits

Reference geometry: Vladimir Petkovic / Khronos ScatteringSkull, CC0 1.0, as credited in the saved FeatureScript and the asset README.

- [Xeon — Skull in Onshape](https://cad.onshape.com/documents/96aebf30b72ce6df1badf456/w/f91b9825c8a19c3fe01f44b3/e/e7915f1da83ac3bb37acfd75)
- [Khronos — ScatteringSkull](https://github.com/KhronosGroup/glTF-Sample-Assets/blob/main/Models/ScatteringSkull/README.md)
- [Onshape — Feature Studios](https://cad.onshape.com/help/Content/FeatureStudio/feature_studios.htm)
- [Onshape — Exporting files](https://cad.onshape.com/help/Content/File/exporting_files.htm)
- [OpenAI — GPT-6 Astra](https://developers.openai.com/api/docs/models/gpt-6-astra)