digispark-with-cable.scad

   1 // -*- C -*-
   2
   3 include <utils.scad>
   4
   5 //tongue_w = 11.92 + 0.4;
   6
   7 usb_w = 12.01 + 0.19;
   8 usb_wall_w = 0.51;
   9 usb_tongue_d = 8.97 - 0.2;
  10 usb_tongue_w_slop = +0.5;
  11 usb_wall_h = 4.54 - 2.04;
  12 usb_ceil_th = 0.425;
  13
  14 side_wall_th = 1.5; // XXXX rename wall_th
  15
  16 board_l = 17.56 + 0.2;
  17 board_w = 19.14 + 0.2;
  18 board_th = 1.92 + 0.1;
  19
  20 sw_to_edge = board_w/2 + 0.1;
  21
  22 front_wall_th = 0.75;
  23 // egress_w = 8.0;
  24
  25 wall_y_min = -board_l - side_wall_th; // XXXX remove
  26 ceil_y_min = wall_y_min - 5;;
  27
  28 small_walls = [
  29                [ [0, 0], [-sw_to_edge, -1.0] ],
  30                [ [sw_to_edge-4.5, -4.5], [sw_to_edge, -5.7] ],
  31 //             [ [3.0, -11.72],              [sw_to_edge, -13.38] ],
  32                [ [-sw_to_edge+3.85, -14.90], [sw_to_edge, -13.38] ],
  33                ];
  34 chip_cutout = [[ -sw_to_edge + 4.20,    -3.75 ],
  35                [ -sw_to_edge + 11.95,  -11.90 ]];
  36
  37 strain_w = 2.0 + 0.5;
  38 strain_t = 1.0 + 0.5;
  39 strain_pitch_across = 5;
  40 strain_pitch_along = 10;
  41 strain_groove_d = 2;
  42 strain_groove_w = 3;
  43
  44 cover_strap_c_d_y = 5.5; // from front of board
  45 cover_registration_sz_y = 2;
  46 cover_registration_sz_z = 3;
  47
  48 cable_space_z = 6;
  49 cable_dia = 5;
  50 bottom_floor_th = 1.5;
  51
  52 fit_gap_z = 0.5;
  53 fit_gap_y = 0.25;
  54 side_x_gap = 0.5;
  55
  56 cover_ceil_th = 0.9;
  57
  58 // calculated
  59
  60 strap_w = strain_w;
  61
  62 top_top_z = usb_wall_h;
  63 top_base_z = -board_th;
  64 bottom_base_z = top_base_z - cable_space_z - bottom_floor_th;;
  65
  66 front_y_max = front_wall_th;
  67 main_y_min = -board_l - side_wall_th;
  68
  69 strain_0_y_c = main_y_min - strain_w/2;
  70 strain_1_y_c = strain_0_y_c - strain_pitch_along;
  71 total_y_min = strain_1_y_c - strain_w/2 - side_wall_th;
  72
  73 bottom_wall_top_z = (top_top_z + top_base_z) * 0.5 - fit_gap_z/2;
  74 cover_wall_bot_z  = (top_top_z + top_base_z) * 0.5 + fit_gap_z/2;
  75 cover_top_z  = top_top_z + cover_ceil_th;
  76
  77 top_side_wall_x = +board_w/2 + side_wall_th;
  78 total_side_wall_x = top_side_wall_x + side_wall_th + side_x_gap;
  79
  80 cover_registration_c_dy = -cover_strap_c_d_y - strap_w/2
  81   - side_wall_th - cover_registration_sz_y/2;
  82
  83 module BothSides(){
  84   for (m=[0,1]) {
  85     mirror([m,0,0]) {
  86       children();
  87     }
  88   }
  89 }
  90 module FrontWallsPlan(slop) {
  91   BothSides(){
  92     rectfromto([ -board_w/2 - side_wall_th,    0             ],
  93                [ -usb_w/2 - slop,              front_wall_th ]);
  94   }
  95 }
  96 module TopSmallWallsPlan() {
  97   for (m=[0,1]) {
  98     mirror([m,0]) {
  99       rectfromto([ -usb_w/2,              -0.01        ],
 100                  [ -usb_w/2 + usb_wall_w, usb_tongue_d ]);
 101     }
 102   }
 103   FrontWallsPlan(0);
 104   for (w=small_walls) {
 105     rectfromto(w[0], w[1]);
 106   }
 107 }
 108 module TopCeilPlan() {
 109   difference(){
 110     BothSides(){
 111       rectfromto([ -usb_w/2,              -0.01        ],
 112                  [ 0.1,                   usb_tongue_d ]);
 113       rectfromto([ -board_w/2 - side_wall_th, 0            ],
 114                  [ 0.1,                       ceil_y_min   ]);
 115     }
 116     rectfromto(chip_cutout[0], chip_cutout[1]);
 117   }
 118 }
 119 module TopMainWallsPlan() {
 120   BothSides(){
 121     rectfromto([ -board_w/2 - side_wall_th, 0          ],
 122                [ -board_w/2,                wall_y_min ]);
 123   }
 124   FrontWallsPlan(usb_tongue_w_slop);
 125   rectfromto([ -board_w/2 - side_wall_th + 0, -      board_l   ],
 126              [ +board_w/2 + side_wall_th,            total_y_min ]);
 127 }
 128
 129 module CoverRegistrations(){
 130   linextr_y_xz(cover_registration_c_dy - strap_w/2,
 131                cover_registration_c_dy + strap_w/2) {
 132     difference(){
 133       rectfromto([ -total_side_wall_x,
 134                           cover_wall_bot_z - cover_registration_sz_z  ],
 135                  [ +total_side_wall_x, cover_top_z ]);
 136       hull(){
 137         TopElevationForCutout();
 138         translate([0, -20]) TopElevationForCutout();
 139       }
 140     }
 141   }
 142 }
 143
 144 module Top(){ ////toplevel
 145   difference(){
 146     union(){
 147       linextr(0, usb_wall_h)
 148         TopSmallWallsPlan();
 149       linextr(usb_wall_h - usb_ceil_th, usb_wall_h)
 150         TopCeilPlan();
 151       linextr(-board_th, usb_wall_h)
 152         TopMainWallsPlan();
 153       BothSides()
 154         linextr(cover_wall_bot_z, top_top_z)
 155         rectfromto([ -(board_w/2 + 0.1),  total_y_min             ],
 156                    [ -total_side_wall_x,  main_y_min - fit_gap_y  ]);
 157     }
 158
 159     for (y_c = [strain_0_y_c, strain_1_y_c]) {
 160       for (x_c = [-1,+1] * strain_pitch_across/2) {
 161         translate([x_c, y_c, 0])
 162           linextr(-20, 20)
 163           square([ strain_t, strain_w ], center=true);
 164       }
 165     }
 166     linextr_y_xz(total_y_min-1, main_y_min)
 167       translate([0, top_base_z])
 168       scale([1, strain_groove_d/strain_groove_w])
 169       circle(strain_groove_w/2, $fn = 8);
 170   }
 171 }
 172
 173 module TopElevationForCutout(){
 174     rectfromto([ -(top_side_wall_x + side_x_gap), top_base_z ],
 175                [ +(top_side_wall_x + side_x_gap), top_top_z  ]);
 176 }
 177 module BottomMainElevation(){
 178   difference(){
 179     rectfromto([ -total_side_wall_x, bottom_base_z        ],
 180                [ +total_side_wall_x, bottom_wall_top_z    ]);
 181
 182     TopElevationForCutout();
 183   }
 184 }
 185 module Bottom(){ ////toplevel
 186   difference(){
 187     union(){
 188       linextr_y_xz(total_y_min, front_y_max)
 189         BottomMainElevation();
 190     }
 191
 192     linextr_y_xz(total_y_min + side_wall_th,
 193                  front_y_max - side_wall_th)
 194       rectfromto([ -board_w/2, bottom_base_z + bottom_floor_th ],
 195                  [ +board_w/2, 20         ]);
 196
 197     linextr_y_xz(total_y_min - 1,
 198                  total_y_min + side_wall_th + 1){
 199       translate([ 0, top_base_z ]){
 200         hull(){
 201           translate([ 0, -cable_dia/2 ])
 202             circle(r = cable_dia/2, $fa = 10, $fs = 1);
 203           square([ cable_dia, 0.1 ], center=true);
 204         }
 205       }
 206     }
 207     minkowski(){
 208       CoverRegistrations();
 209       cube([ 1, fit_gap_y*2, fit_gap_z*2 ], center=true);
 210     }
 211   }
 212 }
 213
 214 module CoverMainElevation(){
 215   difference(){
 216     rectfromto([ -total_side_wall_x, cover_wall_bot_z        ],
 217                [ +total_side_wall_x, cover_top_z    ]);
 218
 219     TopElevationForCutout();
 220   }
 221 }
 222 module Cover(){ ////toplevel
 223   linextr_y_xz(main_y_min, front_y_max)
 224     CoverMainElevation();
 225   CoverRegistrations();
 226 }
 227
 228 module BottomDemo(){ ////toplevel
 229   translate([0, 0, -0.25]) Bottom();
 230   %Top();
 231   translate([0, 0, +0.25]) Cover();
 232 }