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/* A small, arbitrary unit to guard against rounding errors */
eps = 0.1;
alot = 1000;
/* Base PCB size */
pcb_width = 50;
pcb_height = 70;
/* Extra space around PCB */
pcb_extra = 1;
/* Offset of screw hole centers from left/right/top/bottom side of board */
screw_offx_l = 5;
screw_offx_r = 5;
screw_offx_t = 5;
screw_offx_b = 5;
/* Thickness of bottom, walls, lid (middle sections) */
bottom_thickness = 1.5;
wall_thickness = 1.5;
lid_thickness = 1.5;
/* Outside corner radius */
corner_radius_wall = 3;
corner_radius_lid = 2;
screw_base_dia = 8;
screw_base_h = 5;
screw_nut_dia = 5.4;
screw_nut_h = 6;
screw_hole_dia = 4.0;
screw_hole_h = 6;
board_thickness = 1.6;
height_above_board = 18;
height_lid_inner = 1;
lid_lip_depth = 1;
lid_lip_width = 1;
lid_lip_extra = 1;
clamp_tube_dia = screw_base_dia;
clamp_tube_h = 0; //height_above_board+height_lid_inner;
clamp_tube_base_extra = 2;
screw_head_hole_dia = 6.5;
screw_head_hole_depth = 3;
module rounded_rect(w, h, r) {
hull(){
translate([w/2-r, h/2-r]) circle(r);
translate([-(w/2-r), h/2-r]) circle(r);
translate([w/2-r, -(h/2-r)]) circle(r);
translate([-(w/2-r), -(h/2-r)]) circle(r);
}
}
module shell(thickness, inner_height, inner_extra, radius_horiz) {
d = thickness + inner_height;
rh=radius_horiz;
difference(){
r = corner_radius_wall;
w = pcb_width+pcb_extra+2*wall_thickness;
h = pcb_height+pcb_extra+2*wall_thickness;
hull() {
translate([0, 0, rh]) linear_extrude(height=d-rh) rounded_rect(w, h, r);
linear_extrude(height=eps) rounded_rect(w-2*rh, h-2*rh, r);
}
iw = pcb_width+inner_extra;
ih = pcb_height+inner_extra;
translate([-iw/2, -ih/2, bottom_thickness]) cube([iw, ih, h]);
}
}
module single_screw_base() {
translate([0, 0, bottom_thickness-eps]) linear_extrude(height=screw_base_h+eps) {
circle(d=screw_base_dia);
translate([-screw_base_dia/2, 0]) square([alot, alot]);
translate([0, -screw_base_dia/2]) square([alot, alot]);
}
}
w = pcb_width;
h = pcb_height;
e = pcb_extra;
l = screw_offx_l;
r = screw_offx_r;
t = screw_offx_t;
b = screw_offx_b;
s1_pos = [w/2-l, h/2-b];
s2_pos = [-w/2+r, -h/2+t];
s3_pos = [w/2-l, -h/2+t];
s4_pos = [-w/2+r, h/2-b];
module screw_bases() {
intersection() {
union() {
translate(s1_pos) single_screw_base();
translate(s2_pos) mirror([1,1,0]) single_screw_base();
translate(s3_pos) mirror([0,1,0]) single_screw_base();
translate(s4_pos) mirror([1,0,0]) single_screw_base();
}
cube([w+e+eps, h+e+eps, alot], center=true);
}
}
module single_screw_hole() {
translate([0, 0, bottom_thickness+screw_base_h+eps])
mirror([0,0,1])
union() {
cylinder(h=screw_nut_h+eps, d=screw_nut_dia);
cylinder(h=screw_hole_h+eps, d=screw_hole_dia);
}
}
module screw_holes() {
translate(s1_pos) single_screw_hole();
translate(s2_pos) mirror([1,1,0]) single_screw_hole();
translate(s3_pos) mirror([0,1,0]) single_screw_hole();
translate(s4_pos) mirror([1,0,0]) single_screw_hole();
}
conn_1_y = 12.0;
conn_1_l = 20.0;
conn_1_h = 7;
conn_2_y = conn_1_y+conn_1_l+6.0;
conn_2_l = conn_1_l;
conn_2_h = conn_1_h;
conn_pwr_y = 12.5;
conn_pwr_l = 10.0;
conn_pwr_h = 10;
conn_extra = 1;
module conn_holes() {
e = conn_extra;
translate([0, -e/2, -e/2])
translate([0, 0, bottom_thickness+screw_base_h+board_thickness])
translate([-pcb_width/2, -pcb_height/2]) {
translate([-alot, conn_1_y]) cube([alot, conn_1_l+e, conn_1_h+e]);
translate([-alot, conn_2_y]) cube([alot, conn_2_l+e, conn_2_h+e]);
translate([0, conn_pwr_y]) cube([alot, conn_pwr_l+e, conn_pwr_h+e]);
}
}
module base() {
difference() {
union() {
screw_bases();
shell(bottom_thickness,
screw_base_h + board_thickness + height_above_board,
pcb_extra,
radius_horiz=0);
}
screw_holes();
conn_holes();
}
}
module single_clamp_stud_part(liph, clamp_tube_h, extra) {
translate([0, 0, lid_thickness-eps]) union() {
cylinder(h=clamp_tube_h, d=clamp_tube_dia+extra);
linear_extrude(height=liph+eps) {
translate([-clamp_tube_dia/2-extra/2, 0]) square([alot, alot]);
translate([0, -clamp_tube_dia/2-extra/2]) square([alot, alot]);
}
}
}
module single_clamp_stud(liph) {
e = clamp_tube_base_extra;
single_clamp_stud_part(liph, liph+eps, e);
single_clamp_stud_part(liph, clamp_tube_h, 0);
}
module lid_screw_hole() {
cylinder(h=alot, d=screw_hole_dia);
cylinder(h=screw_head_hole_depth+eps, d=screw_head_hole_dia);
}
module lid() {
e = lid_lip_extra;
iw = pcb_width+pcb_extra-e+eps;
ih = pcb_height+pcb_extra-e+eps;
liph = lid_lip_depth+height_lid_inner;
difference() {
union() {
shell(lid_thickness,
height_lid_inner,
inner_extra=-eps,
radius_horiz=corner_radius_lid);
difference() {
translate([-iw/2, -ih/2, lid_thickness-eps]) cube([iw, ih, liph+eps]);
minkowski() {
translate([-iw/2+e/2+liph, -ih/2+e/2+liph, lid_thickness-eps]) cube([iw-e-liph*2, ih-e-liph*2, eps]);
cylinder(d1=0, d2=2*liph+2*eps, h=2*liph+2*eps);
};
}
intersection() {
translate([-iw/2, -ih/2, lid_thickness-eps]) cube([iw, ih, alot]);
union() {
translate(s1_pos) single_clamp_stud(liph);
translate(s2_pos) mirror([1,1,0]) single_clamp_stud(liph);
translate(s3_pos) mirror([0,1,0]) single_clamp_stud(liph);
translate(s4_pos) mirror([1,0,0]) single_clamp_stud(liph);
}
}
}
translate([0, 0, -eps]) {
translate(s1_pos) lid_screw_hole();
translate(s2_pos) lid_screw_hole();
translate(s3_pos) lid_screw_hole();
translate(s4_pos) lid_screw_hole();
}
}
}
module enclosure() {
intersection() {
//translate([-pcb_width, -40, 0]) cube (35, 20, 20);
//translate([-pcb_width-15, 0, 0]) base();
};
intersection() {
//translate([-alot/2, -10, -alot/2]) cube ([alot, 20, alot]);
union () {
render() lid();
render() translate([0,0,eps]) mirror([0,0,1]) intersection() {
translate([-alot/2, -alot/2, 0]) cube([alot, alot, alot]);
translate([0,0,-0.2]) scale([0.3, 0.3, 0.04]) surface("depthmap_03.png", center=true);
};
};
};
}
enclosure($fn=25);
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