329 lines
10 KiB
OpenSCAD
329 lines
10 KiB
OpenSCAD
// Copyright 2022 Thorsten Brehm
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// brehmt (at) gmail dot com
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module imprint(x,y,z)
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{
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Font = "Liberation Sans:style=Bold";
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FontSize = 3;
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translate([x,y,z])
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rotate([270,0,0])
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{
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linear_extrude(height = 0.4) { text(IMPRINT, font = Font, size = FontSize, halign="center", valign="bottom"); }
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}
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}
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// cable strain relief (attached to the top shell)
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module makeTopCableStrainRelief(height)
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{
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translate([ScrewPostDiameter, 0, 0])
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rotate([180,0,0]) screwPost(height, ScrewPostDiameter+1, ScrewDiameter, height, 0);
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translate([-RearWallCableGapWidth, 0, 0])
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rotate([180,0,0]) screwPost(height, ScrewPostDiameter+1, ScrewDiameter, height, 0);
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StrainReliefWidth=3;
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translate([-RearWallCableGapWidth+ScrewPostDiameter/2, -StrainReliefWidth/2, -height])
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cube([RearWallCableGapWidth, StrainReliefWidth, height]);
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}
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// little mounting point, so the base plate does not drop when glueing to the top shell
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module makeGlueHelper(Width)
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{
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SupportAngle = 35;
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intersection()
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{
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union()
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{
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translate([-20, 0, 0])
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rotate([0, 0, SupportAngle])
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translate([-20,-25,-Width/2])
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cube([40, 50, Width]);
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}
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translate([0,0,-Width/2]) cube([40,50,Width]);
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}
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}
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// little mounting points to help when glueing the base to the top shell
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module makeGlueMountingPoints()
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{
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SupportWidth = 5; // 10mm
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//SupportXOffset = -36.9;
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SupportXOffset1 = -28;//34.9;
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//SupportXOffset2 = SupportXOffset1+32.1;
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SupportXOffset2 = 32.1;
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// support for bottom curved edges
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SupportYOffset = 0;
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FrontZ = FrontPanelZLedge+FrontPanelZOffset+SKIN*5; // front position
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RearZ = BoxZ_Depth-RearWallZLedge-RearWallZOffset-5*SKIN; // rear position
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intersection()
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{
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union()
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{
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// strain relief, attached to the top shell (which is the most rigid structure)
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if (STRAIN_RELIEF == "yes")
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translate([BoxX_Width-RearWallGap-RearWallCableGapXOffset-7, BoxY_Height, BoxZ_Depth-RearWallZLedge-RearWallZOffset])
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rotate([65+180,0,0]) makeTopCableStrainRelief(7);
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for (z=[FrontZ, RearZ, (FrontZ+RearZ)/2])
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{
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// right
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translate([0, SupportYOffset, z]) makeGlueHelper(SupportWidth);
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// left
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translate([BoxX_Width, SupportYOffset, z]) rotate([0, 180, 0]) makeGlueHelper(SupportWidth);
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}
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}
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// cut away anything which is outside the shell
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outerBox(SKIN, BoxX_Width, BoxY_Height, BoxZ_Depth, Box_Corner_Radius);
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}
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}
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module makeTopStiffeners()
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{
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SupportWidth = 15;
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// front right
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translate([0, BoxY_Height-SupportWidth, FrontPanelZOffset+SKIN*2+15]) rotate([0,90,0]) prism(SKIN, SupportWidth, SupportWidth);
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// front left
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translate([BoxX_Width, BoxY_Height-SupportWidth, FrontPanelZOffset+SKIN+15]) rotate([0,270,0]) prism(SKIN, SupportWidth, 10);
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// center right
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translate([0, BoxY_Height-SupportWidth, BoxZ_Depth/2]) rotate([0,90,0]) prism(SKIN, SupportWidth, SupportWidth);
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// center left
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translate([BoxX_Width, BoxY_Height-SupportWidth, BoxZ_Depth/2-SKIN]) rotate([0,270,0]) prism(SKIN, SupportWidth, SupportWidth);
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// rear right
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translate([0, BoxY_Height-SupportWidth, BoxZ_Depth-RearWallZOffset-SKIN-3-2]) rotate([0,90,0]) prism(SKIN, SupportWidth, SupportWidth);
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// rear left
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translate([BoxX_Width, BoxY_Height-SupportWidth, BoxZ_Depth-RearWallZOffset-3-SKIN*2-2]) rotate([0,270,0]) prism(SKIN, SupportWidth, SupportWidth);
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}
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module roundedEdge()
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{
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translate([-SKIN, 0, 30]) rotate([270, 0, 0]) roundedCube(2, 30, SKIN, 1);
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}
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module roundCorner()
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{
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$fn=24;
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Radius = TopGrooveCornerRadius/2;
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translate([0,1,0]) rotate([270, 0, 0])
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translate([-Radius-TopGrooveYDepth, -Radius-TopGrooveYDepth, 0])
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intersection()
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{
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torus(Radius, TopGrooveYDepth);
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cube([Radius*2, Radius*2, TopGrooveYDepth]);
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}
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}
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module makeRoundGapEdges()
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{
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// front left
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translate([FrontGapX-FrontGapWidth/2-1, -SKIN, 0]) roundedEdge();
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translate([FrontGapX+FrontGapWidth/2+1, -SKIN, 0]) roundedEdge();
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// front right
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translate([BoxX_Width-FrontGapX-FrontGapWidth/2-1, -SKIN, 0]) roundedEdge();
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translate([BoxX_Width-FrontGapX+FrontGapWidth/2+1, -SKIN, 0]) roundedEdge();
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// rear left
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translate([FrontGapX-FrontGapWidth/2-1, -SKIN, BoxZ_Depth-30]) roundedEdge();
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// rear right
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translate([BoxX_Width-FrontGapX+FrontGapWidth/2+1, -SKIN, BoxZ_Depth-30]) roundedEdge();
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}
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module makeGaps()
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{
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// front gaps
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translate([FrontGapX-FrontGapWidth/2-1, -SKIN, 0]) cube([FrontGapWidth+2, SKIN*2, FrontGapY]);
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translate([BoxX_Width-FrontGapX-FrontGapWidth/2-1, -SKIN, 0]) cube([FrontGapWidth+2, SKIN*2, FrontGapY]);
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// rear gap
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translate([FrontGapX-FrontGapWidth/2-1, -SKIN, BoxZ_Depth-10]) cube([BoxX_Width-2*FrontGapX+FrontGapWidth+2, SKIN*2, 10]);
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}
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module ventilationCut()
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{
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translate([-SKIN, BoxY_Height-VentilationYHeight,BoxZ_Depth-VentilationZOffset]) rotate([0, 90, 0])
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roundedCube(VentilationWidth, VentilationYHeight, SKIN, VentilationWidth/2);
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translate([BoxX_Width, BoxY_Height-VentilationYHeight,BoxZ_Depth-VentilationZOffset]) rotate([0, 90, 0])
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roundedCube(VentilationWidth, VentilationYHeight, SKIN, VentilationWidth/2);
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translate([-SKIN-VentilationYHeight+VentilationXLength, BoxY_Height+SKIN,BoxZ_Depth-VentilationZOffset]) rotate([90, 90, 0])
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roundedCube(VentilationWidth, VentilationYHeight, SKIN+5, VentilationWidth/2);
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translate([BoxX_Width-VentilationXLength, BoxY_Height+SKIN,BoxZ_Depth-VentilationZOffset]) rotate([90, 90, 0])
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roundedCube(VentilationWidth, VentilationYHeight, SKIN+5, VentilationWidth/2);
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}
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module makeVentilation()
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{
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for (z = [0 : 1: VentilationCount-1])
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{
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translate([0, 0, -z*VentilationZDistance]) ventilationCut();
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}
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}
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module makeScrewHoles()
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{
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// front hole
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translate([FrontGapX/2, -SKIN, FrontPanelZOffset+FrontPanelZLedge/2]) rotate([270, 0, 0])
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hole(ScrewDiameter, 10);
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// front hole
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translate([BoxX_Width-FrontGapX/2, -SKIN, FrontPanelZOffset+FrontPanelZLedge/2]) rotate([270, 0, 0])
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hole(ScrewDiameter, 10);
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// rear hole
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translate([FrontGapX/2, -SKIN , BoxZ_Depth-RearWallZOffset-RearWallZLedge/2]) rotate([270, 0, 0])
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hole(ScrewDiameter, 10);
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// rear hole
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translate([BoxX_Width-FrontGapX/2, -SKIN, BoxZ_Depth-RearWallZOffset-RearWallZLedge/2]) rotate([270, 0, 0])
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hole(ScrewDiameter, 10);
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// rear PCB holes
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translate([BoxX_Width/2-PcbXWidth/2, 0, PcbZOfs])
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{
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translate([PcbScrewDistance, -SKIN,PcbZDepth-PcbScrewDistance]) rotate([270, 0, 0]) hole(PcbScrewDiameter, SKIN);
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translate([PcbXWidth-PcbScrewDistance, -SKIN,PcbZDepth-PcbScrewDistance]) rotate([270, 0, 0]) hole(PcbScrewDiameter, SKIN);
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}
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}
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GrooveSupportZOffset = (BoxZ_Depth-2*TopGrooveZLength)/3;
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GrooveXOfs = BoxX_Width/2-(TopGrooveXWidth+4)/2;
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module makeTopGroovesSupport()
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{
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translate([GrooveXOfs, BoxY_Height-TopGrooveYDepth, GrooveSupportZOffset+TopGrooveZLength+2]) rotate([270, 0, 0])
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roundedCube(TopGrooveXWidth+4, TopGrooveZLength+4, TopGrooveYDepth, TopGrooveCornerRadius);
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translate([GrooveXOfs, BoxY_Height-TopGrooveYDepth, GrooveSupportZOffset*2+TopGrooveZLength*2+2]) rotate([270, 0, 0])
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roundedCube(TopGrooveXWidth+4, TopGrooveZLength+4, TopGrooveYDepth, TopGrooveCornerRadius);
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}
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module makeTopGroovesEdges()
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{
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for (z=[GrooveSupportZOffset,2*GrooveSupportZOffset+TopGrooveZLength])
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translate([GrooveXOfs+2, BoxY_Height-TopGrooveYDepth+SKIN, z])
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{
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// right edge
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translate([0, 0, 4+TopGrooveZLength/2-5])
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cylinderLedge(TopGrooveYDepth, TopGrooveZLength);
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// left edge
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translate([TopGrooveXWidth, 0, 4+TopGrooveZLength/2-5])
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rotate([0, 180, 0]) cylinderLedge(TopGrooveYDepth, TopGrooveZLength);
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// front edge
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translate([TopGrooveXWidth/2, 0, 0])
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rotate([0, 270, 0]) cylinderLedge(TopGrooveYDepth, TopGrooveXWidth);
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// rear edge
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translate([TopGrooveXWidth/2, 0, TopGrooveZLength])
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rotate([0, 90, 0]) cylinderLedge(TopGrooveYDepth, TopGrooveXWidth);
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// rear right corner
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translate([TopGrooveXWidth, -1, 0]) roundCorner();
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// rear left corner
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translate([0, -1, 0]) rotate([0, 90, 0]) roundCorner();
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// front right corner
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translate([TopGrooveXWidth, -1, TopGrooveZLength]) rotate([0, 270, 0]) roundCorner();
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// front left corner
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translate([0, -1, TopGrooveZLength]) rotate([0, 180, 0]) roundCorner();
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}
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}
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module makeTopGrooves()
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{
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GrooveZOffset = (BoxZ_Depth-2*TopGrooveZLength)/3;
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translate([BoxX_Width/2-TopGrooveXWidth/2, BoxY_Height-TopGrooveYDepth+SKIN, GrooveZOffset+TopGrooveZLength]) rotate([270, 0, 0])
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roundedCube(TopGrooveXWidth, TopGrooveZLength, TopGrooveYDepth, TopGrooveCornerRadius);
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translate([BoxX_Width/2-TopGrooveXWidth/2, BoxY_Height-TopGrooveYDepth+SKIN, GrooveZOffset*2+TopGrooveZLength*2]) rotate([270, 0, 0])
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roundedCube(TopGrooveXWidth, TopGrooveZLength, TopGrooveYDepth, TopGrooveCornerRadius);
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}
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// little supports to prevent the front and rear panels from bending into the case
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module makeTopPanelSupports()
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{
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Distance = 10; // distance of the supports from the left/right edge of the box
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SupportWidth = 3; // x,z size of the supports
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SupportYHeight = 4; // y size of the supports (cube)
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// front left
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translate([BoxX_Width-5, BoxY_Height-SupportYHeight, FrontPanelZOffset+SKIN])
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cube([SupportWidth, SupportYHeight, SupportWidth]);
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// front right
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translate([18, BoxY_Height-SupportYHeight, FrontPanelZOffset+SKIN])
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cube([SupportWidth, SupportYHeight, SupportWidth]);
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// front center
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translate([BoxX_Width/2-4, BoxY_Height-SupportYHeight, FrontPanelZOffset+SKIN])
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cube([SupportWidth, SupportYHeight, SupportWidth]);
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// rear
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translate([BoxX_Width-RearWallCableGapXOffset/2-SupportWidth,
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BoxY_Height-SupportYHeight, BoxZ_Depth-RearWallZOffset-SKIN-SupportWidth])
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cube([SupportWidth, SupportYHeight, SupportWidth]);
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translate([Distance, BoxY_Height-SupportYHeight, BoxZ_Depth-RearWallZOffset-SKIN-SupportWidth])
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cube([SupportWidth, SupportYHeight, SupportWidth]);
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}
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module makeThing()
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{
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union()
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{
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difference()
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{
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union()
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{
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box(SKIN, BoxX_Width, BoxY_Height, BoxZ_Depth, Box_Corner_Radius);
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makeTopGroovesSupport();
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makeGlueMountingPoints();
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}
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makeGaps();
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makeVentilation();
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makeTopGrooves();
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makeScrewHoles();
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if (prototype == "yes")
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{
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removePrototypeAreas();
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}
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}
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makeRoundGapEdges();
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makeTopGroovesEdges();
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makeTopPanelSupports();
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makeTopStiffeners();
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}
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}
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module makeMask()
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{
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XOffs = 3.5*ScalingFactor;
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translate([XOffs/2, -BoxY_Height, 0]) cube([BoxX_Width-XOffs, BoxY_Height+SKIN, BoxZ_Depth]);
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}
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module makeTop()
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{
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difference()
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{
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makeThing();
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makeMask();
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}
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}
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module makeBottom()
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{
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intersection()
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{
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makeThing();
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makeMask();
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}
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imprint(BoxX_Width/2,0,BoxZ_Depth-RearWallZLedge-RearWallZOffset);
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}
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