FloppyEmuDiskIIEnclosure/scad/components/top_and_bottom.scad

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2022-05-16 22:06:31 +00:00
// Copyright 2022 Thorsten Brehm
// brehmt (at) gmail dot com
module imprint(x,y,z)
{
Font = "Liberation Sans:style=Bold";
FontSize = 3;
translate([x,y,z])
rotate([270,0,0])
{
linear_extrude(height = 0.4) { text(IMPRINT, font = Font, size = FontSize, halign="center", valign="bottom"); }
}
}
// little mounting point, so the base plate does not drop when glueing to the top shell
module makeGlueHelper(Width)
{
SupportAngle = 35;
intersection()
{
union()
{
translate([-20, 0, 0])
rotate([0, 0, SupportAngle])
translate([-20,-25,-Width/2])
cube([40, 50, Width]);
}
translate([0,0,-Width/2]) cube([40,50,Width]);
}
}
// little mounting points to help when glueing the base to the top shell
module makeGlueMountingPoints()
{
SupportWidth = 5; // 10mm
//SupportXOffset = -36.9;
SupportXOffset1 = -28;//34.9;
//SupportXOffset2 = SupportXOffset1+32.1;
SupportXOffset2 = 32.1;
// support for bottom curved edges
SupportYOffset = 0;
FrontZ = FrontPanelZLedge+FrontPanelZOffset+SKIN*5; // front position
RearZ = BoxZ_Depth-RearWallZLedge-RearWallZOffset-5*SKIN; // rear position
intersection()
{
union()
{
for (z=[FrontZ, RearZ, (FrontZ+RearZ)/2])
{
// right
translate([0, SupportYOffset, z]) makeGlueHelper(SupportWidth);
// left
translate([BoxX_Width, SupportYOffset, z]) rotate([0, 180, 0]) makeGlueHelper(SupportWidth);
}
}
// cut away anything which is outside the shell
outerBox(SKIN, BoxX_Width, BoxY_Height, BoxZ_Depth, Box_Corner_Radius);
}
}
module makeTopStiffeners()
{
SupportWidth = 15;
// front right
translate([0, BoxY_Height-SupportWidth, FrontPanelZOffset+SKIN*2+15]) rotate([0,90,0]) prism(SKIN, SupportWidth, SupportWidth);
// front left
translate([BoxX_Width, BoxY_Height-SupportWidth, FrontPanelZOffset+SKIN+15]) rotate([0,270,0]) prism(SKIN, SupportWidth, 10);
// center right
translate([0, BoxY_Height-SupportWidth, BoxZ_Depth/2]) rotate([0,90,0]) prism(SKIN, SupportWidth, SupportWidth);
// center left
translate([BoxX_Width, BoxY_Height-SupportWidth, BoxZ_Depth/2-SKIN]) rotate([0,270,0]) prism(SKIN, SupportWidth, SupportWidth);
// rear right
translate([0, BoxY_Height-SupportWidth, BoxZ_Depth-RearWallZOffset-SKIN-3-2]) rotate([0,90,0]) prism(SKIN, SupportWidth, SupportWidth);
// rear left
translate([BoxX_Width, BoxY_Height-SupportWidth, BoxZ_Depth-RearWallZOffset-3-SKIN*2-2]) rotate([0,270,0]) prism(SKIN, SupportWidth, SupportWidth);
}
module roundedEdge()
{
translate([-SKIN, 0, 30]) rotate([270, 0, 0]) roundedCube(2, 30, SKIN, 1);
}
module roundCorner()
{
$fn=24;
Radius = TopGrooveCornerRadius/2;
translate([0,1,0]) rotate([270, 0, 0])
translate([-Radius-TopGrooveYDepth, -Radius-TopGrooveYDepth, 0])
intersection()
{
torus(Radius, TopGrooveYDepth);
cube([Radius*2, Radius*2, TopGrooveYDepth]);
}
}
module makeRoundGapEdges()
{
// front left
translate([FrontGapX-FrontGapWidth/2-1, -SKIN, 0]) roundedEdge();
translate([FrontGapX+FrontGapWidth/2+1, -SKIN, 0]) roundedEdge();
// front right
translate([BoxX_Width-FrontGapX-FrontGapWidth/2-1, -SKIN, 0]) roundedEdge();
translate([BoxX_Width-FrontGapX+FrontGapWidth/2+1, -SKIN, 0]) roundedEdge();
// rear left
translate([FrontGapX-FrontGapWidth/2-1, -SKIN, BoxZ_Depth-30]) roundedEdge();
// rear right
translate([BoxX_Width-FrontGapX+FrontGapWidth/2+1, -SKIN, BoxZ_Depth-30]) roundedEdge();
}
module makeGaps()
{
// front gaps
translate([FrontGapX-FrontGapWidth/2-1, -SKIN, 0]) cube([FrontGapWidth+2, SKIN*2, FrontGapY]);
translate([BoxX_Width-FrontGapX-FrontGapWidth/2-1, -SKIN, 0]) cube([FrontGapWidth+2, SKIN*2, FrontGapY]);
// rear gap
translate([FrontGapX-FrontGapWidth/2-1, -SKIN, BoxZ_Depth-10]) cube([BoxX_Width-2*FrontGapX+FrontGapWidth+2, SKIN*2, 10]);
}
module ventilationCut()
{
translate([-SKIN, BoxY_Height-VentilationYHeight,BoxZ_Depth-VentilationZOffset]) rotate([0, 90, 0])
roundedCube(VentilationWidth, VentilationYHeight, SKIN, VentilationWidth/2);
translate([BoxX_Width, BoxY_Height-VentilationYHeight,BoxZ_Depth-VentilationZOffset]) rotate([0, 90, 0])
roundedCube(VentilationWidth, VentilationYHeight, SKIN, VentilationWidth/2);
translate([-SKIN-VentilationYHeight+VentilationXLength, BoxY_Height+SKIN,BoxZ_Depth-VentilationZOffset]) rotate([90, 90, 0])
roundedCube(VentilationWidth, VentilationYHeight, SKIN+5, VentilationWidth/2);
translate([BoxX_Width-VentilationXLength, BoxY_Height+SKIN,BoxZ_Depth-VentilationZOffset]) rotate([90, 90, 0])
roundedCube(VentilationWidth, VentilationYHeight, SKIN+5, VentilationWidth/2);
}
module makeVentilation()
{
for (z = [0 : 1: VentilationCount-1])
{
translate([0, 0, -z*VentilationZDistance]) ventilationCut();
}
}
module makeScrewHoles()
{
// front hole
translate([FrontGapX/2, -SKIN, FrontPanelZOffset+FrontPanelZLedge/2]) rotate([270, 0, 0])
hole(ScrewDiameter, 10);
// front hole
translate([BoxX_Width-FrontGapX/2, -SKIN, FrontPanelZOffset+FrontPanelZLedge/2]) rotate([270, 0, 0])
hole(ScrewDiameter, 10);
// rear hole
translate([FrontGapX/2, -SKIN , BoxZ_Depth-RearWallZOffset-RearWallZLedge/2]) rotate([270, 0, 0])
hole(ScrewDiameter, 10);
// rear hole
translate([BoxX_Width-FrontGapX/2, -SKIN, BoxZ_Depth-RearWallZOffset-RearWallZLedge/2]) rotate([270, 0, 0])
hole(ScrewDiameter, 10);
// rear PCB holes
translate([BoxX_Width/2-PcbXWidth/2, 0, PcbZOfs])
{
translate([PcbScrewDistance, -SKIN,PcbZDepth-PcbScrewDistance]) rotate([270, 0, 0]) hole(PcbScrewDiameter, SKIN);
translate([PcbXWidth-PcbScrewDistance, -SKIN,PcbZDepth-PcbScrewDistance]) rotate([270, 0, 0]) hole(PcbScrewDiameter, SKIN);
}
}
GrooveSupportZOffset = (BoxZ_Depth-2*TopGrooveZLength)/3;
GrooveXOfs = BoxX_Width/2-(TopGrooveXWidth+4)/2;
module makeTopGroovesSupport()
{
translate([GrooveXOfs, BoxY_Height-TopGrooveYDepth, GrooveSupportZOffset+TopGrooveZLength+2]) rotate([270, 0, 0])
roundedCube(TopGrooveXWidth+4, TopGrooveZLength+4, TopGrooveYDepth, TopGrooveCornerRadius);
translate([GrooveXOfs, BoxY_Height-TopGrooveYDepth, GrooveSupportZOffset*2+TopGrooveZLength*2+2]) rotate([270, 0, 0])
roundedCube(TopGrooveXWidth+4, TopGrooveZLength+4, TopGrooveYDepth, TopGrooveCornerRadius);
}
module makeTopGroovesEdges()
{
for (z=[GrooveSupportZOffset,2*GrooveSupportZOffset+TopGrooveZLength])
translate([GrooveXOfs+2, BoxY_Height-TopGrooveYDepth+SKIN, z])
{
// right edge
translate([0, 0, 4+TopGrooveZLength/2-5])
cylinderLedge(TopGrooveYDepth, TopGrooveZLength);
// left edge
translate([TopGrooveXWidth, 0, 4+TopGrooveZLength/2-5])
rotate([0, 180, 0]) cylinderLedge(TopGrooveYDepth, TopGrooveZLength);
// front edge
translate([TopGrooveXWidth/2, 0, 0])
rotate([0, 270, 0]) cylinderLedge(TopGrooveYDepth, TopGrooveXWidth);
// rear edge
translate([TopGrooveXWidth/2, 0, TopGrooveZLength])
rotate([0, 90, 0]) cylinderLedge(TopGrooveYDepth, TopGrooveXWidth);
// rear right corner
translate([TopGrooveXWidth, -1, 0]) roundCorner();
// rear left corner
translate([0, -1, 0]) rotate([0, 90, 0]) roundCorner();
// front right corner
translate([TopGrooveXWidth, -1, TopGrooveZLength]) rotate([0, 270, 0]) roundCorner();
// front left corner
translate([0, -1, TopGrooveZLength]) rotate([0, 180, 0]) roundCorner();
}
}
module makeTopGrooves()
{
GrooveZOffset = (BoxZ_Depth-2*TopGrooveZLength)/3;
translate([BoxX_Width/2-TopGrooveXWidth/2, BoxY_Height-TopGrooveYDepth+SKIN, GrooveZOffset+TopGrooveZLength]) rotate([270, 0, 0])
roundedCube(TopGrooveXWidth, TopGrooveZLength, TopGrooveYDepth, TopGrooveCornerRadius);
translate([BoxX_Width/2-TopGrooveXWidth/2, BoxY_Height-TopGrooveYDepth+SKIN, GrooveZOffset*2+TopGrooveZLength*2]) rotate([270, 0, 0])
roundedCube(TopGrooveXWidth, TopGrooveZLength, TopGrooveYDepth, TopGrooveCornerRadius);
}
// little supports to prevent the front and rear panels from bending into the case
module makeTopPanelSupports()
{
Distance = 10; // distance of the supports from the left/right edge of the box
SupportWidth = 3; // x,z size of the supports
SupportYHeight = 4; // y size of the supports (cube)
// front left
translate([BoxX_Width-5, BoxY_Height-SupportYHeight, FrontPanelZOffset+SKIN])
cube([SupportWidth, SupportYHeight, SupportWidth]);
// front right
translate([18, BoxY_Height-SupportYHeight, FrontPanelZOffset+SKIN])
cube([SupportWidth, SupportYHeight, SupportWidth]);
// front center
translate([BoxX_Width/2-4, BoxY_Height-SupportYHeight, FrontPanelZOffset+SKIN])
cube([SupportWidth, SupportYHeight, SupportWidth]);
// rear
translate([BoxX_Width-RearWallCableGapXOffset/2-SupportWidth,
BoxY_Height-SupportYHeight, BoxZ_Depth-RearWallZOffset-SKIN-SupportWidth])
cube([SupportWidth, SupportYHeight, SupportWidth]);
translate([Distance, BoxY_Height-SupportYHeight, BoxZ_Depth-RearWallZOffset-SKIN-SupportWidth])
cube([SupportWidth, SupportYHeight, SupportWidth]);
}
module makeThing()
{
union()
{
difference()
{
union()
{
box(SKIN, BoxX_Width, BoxY_Height, BoxZ_Depth, Box_Corner_Radius);
makeTopGroovesSupport();
makeGlueMountingPoints();
}
makeGaps();
makeVentilation();
makeTopGrooves();
makeScrewHoles();
if (prototype == "yes")
{
removePrototypeAreas();
}
}
makeRoundGapEdges();
makeTopGroovesEdges();
makeTopPanelSupports();
makeTopStiffeners();
}
}
module makeMask()
{
XOffs = 3.5*ScalingFactor;
translate([XOffs/2, -BoxY_Height, 0]) cube([BoxX_Width-XOffs, BoxY_Height+SKIN, BoxZ_Depth]);
}
module makeTop()
{
difference()
{
makeThing();
makeMask();
}
}
module makeBottom()
{
intersection()
{
makeThing();
makeMask();
}
imprint(BoxX_Width/2,0,BoxZ_Depth-RearWallZLedge-RearWallZOffset);
}