// -*- C -*- patbox_side = 87; patbox_centres = 60.3; lid_thinboxbase_overlap = 5; lid_fatbox_overlap = 12; lid_thinbox_h = 9; lid_fatbox_h = 24; lid_fatbox_switches_h = 6+4; lid_max_switches_w = 70; lid_switches_y_slop = 3; total_len = 260; thinbox_len = 87; rail_overlap = 8; lid_top_wall = 1.5; lid_front_wall = 1.5; lid_side_wall = 1.5; peg_engage_depth = 1; peg_engage_dia = 6.5; peg_main_dia = 9; peg_max_dia = 15; peg_inner_dia = 3.5; peg_top_thick = 1; peg_straight_len = 3; $peg_inner_slop = 0.75; $peg_outer_slop = -0.9; $peg_outer_slop_engage = 0.1; peg_slope = 1; lid_side_slop = 0.5; lid_rail_behindslop = 0.5; lid_rail_strongwall = 2.5; // computed lid_inner_max_h = lid_thinboxbase_overlap + lid_fatbox_h + lid_fatbox_switches_h; lid_inner_min_h = lid_fatbox_overlap + lid_fatbox_switches_h; lid_inner_kink = [thinbox_len, thinbox_len*2]; lid_inner_w_nom = patbox_side; lid_inner_w = lid_inner_w_nom + lid_side_slop * 2; lid_seatline_w = (lid_inner_w - lid_max_switches_w)/2 - lid_switches_y_slop; lid_seatline_h = lid_fatbox_switches_h; peg_main_height = peg_straight_len + (peg_max_dia - peg_main_dia)/2/peg_slope; thinbox_front_z = lid_fatbox_switches_h + lid_fatbox_h - lid_thinbox_h; raillen = patbox_side/2 + rail_overlap; module LidSideProfile(){ polygon([[-lid_top_wall, lid_inner_max_h], [min(lid_inner_kink[0],total_len), lid_inner_max_h], [min(lid_inner_kink[1],total_len), lid_inner_min_h], [total_len, lid_inner_min_h], [total_len, -lid_front_wall], [-lid_top_wall, -lid_front_wall]]); } module RailProfile(lslop=0.1){ yt_base = thinbox_front_z; yt = yt_base - lid_rail_behindslop; pegx = (lid_inner_w_nom - patbox_centres)/2; sw = lid_rail_strongwall; polygon([[-lslop, yt], [pegx - peg_main_dia/2, yt], [pegx - peg_main_dia/2, yt_base - peg_straight_len], [sw, yt_base - peg_straight_len - (pegx - peg_main_dia/2)/peg_slope +sw], [sw, lid_seatline_h - 1], [-lslop, lid_seatline_h - 1]]); } module LidSide(){ overlap = [0.1, 0.1, 0.1]; // main side profile rotate([90,0,0]) linear_extrude(height= lid_side_wall) LidSideProfile(); // seatline translate(-overlap) cube(overlap + [total_len, lid_seatline_w, lid_seatline_h]); // lid front translate([-0.1, -0.1, -lid_front_wall]) cube([total_len+0.1, lid_inner_w/2 + 0.2, lid_front_wall]); // lid top translate([-lid_top_wall, -lid_side_wall, -lid_front_wall]) cube([lid_top_wall, lid_inner_w/2 + 10, lid_front_wall + lid_inner_max_h]); // rail rotate([90,0,90]) translate([0,0,-0.1]) linear_extrude(height=raillen+0.1) //todo RailProfile(); // rail end translate([raillen, 0,0]) intersection(){ rotate_extrude($fn=50) RailProfile(lslop=0); translate([0, 25-0.1, 0]) cube(50, center=true); } } module Lid(){ ////toplevel for (m=[0,1]) mirror([0,m,0]) translate([0, -lid_inner_w/2, 0]) LidSide(); } module PegProfile(){ polygon([[-peg_engage_depth, (peg_engage_dia - $peg_outer_slop_engage)/2], [0, (peg_engage_dia - $peg_outer_slop_engage)/2], [0, (peg_main_dia - $peg_outer_slop)/2], [peg_straight_len, (peg_main_dia - $peg_outer_slop)/2], [peg_main_height, (peg_max_dia - $peg_outer_slop)/2], [peg_main_height+peg_top_thick, (peg_max_dia - $peg_outer_slop)/2], [peg_main_height+peg_top_thick, (peg_inner_dia + $peg_inner_slop)/2], [-peg_engage_depth, (peg_inner_dia + $peg_inner_slop)/2]]); } module Peg(){ ////toplevel echo($peg_outer_slop_engage); rotate_extrude($fn=50) rotate([0,0,-90]) PegProfile(); } module Pegs(){ ////toplevel baseslop = 0.1; dslops = [0, -0.5, -1.0, -1.5]; stride = peg_max_dia + 4; for (i=[0:len(dslops)-1]) { translate([i*stride,0,0]) assign($peg_outer_slop_engage= baseslop + dslops[i]) Peg(); } } module AtFixingCentres(){ for (fc=[-1,+1]) { translate([patbox_side/2 + fc*patbox_centres/2, patbox_side/2, 0]) children(); } } module TopPattressBox(){ difference(){ translate([0,0, -lid_thinbox_h]) cube([patbox_side, patbox_side, lid_thinbox_h]); AtFixingCentres(){ translate([0,0,-10]) cylinder(r=peg_engage_dia/2, h=20); } } } module Demo(){ Lid(); translate([0,0, thinbox_front_z]) rotate([0,180,0]) translate([0, -patbox_side/2, 0]) rotate([0,0,90]) union(){ %TopPattressBox(); color("blue") AtFixingCentres(){ rotate([180,0,0]) Peg(); } } } //LidSide(); //PegProfile(); //Peg(); //Pegs(); //TopPattressBox(); //RailProfile(); //Demo(); //Lid(); //translate([0,0,-lid_fatbox_switches_h]) Lid();