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 cable_space_z = 6;
  45 cable_dia = 5;
  46 bottom_floor_th = 1.5;
  47
  48 fit_gap_z = 0.5;
  49 fit_gap_y = 0.25;
  50 side_x_gap = 0.5;
  51
  52 cover_ceil_th = 0.9;
  53
  54 // calculated
  55
  56 top_top_z = usb_wall_h;
  57 top_base_z = -board_th;
  58 bottom_base_z = top_base_z - cable_space_z - bottom_floor_th;;
  59
  60 front_y_max = front_wall_th;
  61 main_y_min = -board_l - side_wall_th;
  62
  63 strain_0_y_c = main_y_min - strain_w/2;
  64 strain_1_y_c = strain_0_y_c - strain_pitch_along;
  65 total_y_min = strain_1_y_c - strain_w/2 - side_wall_th;
  66
  67 bottom_wall_top_z = (top_top_z + top_base_z) * 0.5 - fit_gap_z/2;
  68 cover_wall_bot_z  = (top_top_z + top_base_z) * 0.5 + fit_gap_z/2;
  69 cover_top_z  = top_top_z + cover_ceil_th;
  70
  71 top_side_wall_x = +board_w/2 + side_wall_th;
  72 total_side_wall_x = top_side_wall_x + side_wall_th + side_x_gap;
  73
  74 module BothSides(){
  75   for (m=[0,1]) {
  76     mirror([m,0]) {
  77       children();
  78     }
  79   }
  80 }
  81 module FrontWallsPlan(slop) {
  82   BothSides(){
  83     rectfromto([ -board_w/2 - side_wall_th,    0             ],
  84                [ -usb_w/2 - slop,              front_wall_th ]);
  85   }
  86 }
  87 module TopSmallWallsPlan() {
  88   for (m=[0,1]) {
  89     mirror([m,0]) {
  90       rectfromto([ -usb_w/2,              -0.01        ],
  91                  [ -usb_w/2 + usb_wall_w, usb_tongue_d ]);
  92     }
  93   }
  94   FrontWallsPlan(0);
  95   for (w=small_walls) {
  96     rectfromto(w[0], w[1]);
  97   }
  98 }
  99 module TopCeilPlan() {
 100   difference(){
 101     BothSides(){
 102       rectfromto([ -usb_w/2,              -0.01        ],
 103                  [ 0.1,                   usb_tongue_d ]);
 104       rectfromto([ -board_w/2 - side_wall_th, 0            ],
 105                  [ 0.1,                       ceil_y_min   ]);
 106     }
 107     rectfromto(chip_cutout[0], chip_cutout[1]);
 108   }
 109 }
 110 module TopMainWallsPlan() {
 111   BothSides(){
 112     rectfromto([ -board_w/2 - side_wall_th, 0          ],
 113                [ -board_w/2,                wall_y_min ]);
 114   }
 115   FrontWallsPlan(usb_tongue_w_slop);
 116   rectfromto([ -board_w/2 - side_wall_th + 0, -      board_l   ],
 117              [ +board_w/2 + side_wall_th,            total_y_min ]);
 118 }
 119
 120 module Top(){ ////toplevel
 121   difference(){
 122     union(){
 123       linextr(0, usb_wall_h)
 124         TopSmallWallsPlan();
 125       linextr(usb_wall_h - usb_ceil_th, usb_wall_h)
 126         TopCeilPlan();
 127       linextr(-board_th, usb_wall_h)
 128         TopMainWallsPlan();
 129       BothSides()
 130         linextr(cover_wall_bot_z, top_top_z)
 131         rectfromto([ -(board_w/2 + 0.1),  total_y_min             ],
 132                    [ -total_side_wall_x,  main_y_min - fit_gap_y  ]);
 133     }
 134
 135     for (y_c = [strain_0_y_c, strain_1_y_c]) {
 136       for (x_c = [-1,+1] * strain_pitch_across/2) {
 137         translate([x_c, y_c, 0])
 138           linextr(-20, 20)
 139           square([ strain_t, strain_w ], center=true);
 140       }
 141     }
 142     linextr_y_xz(total_y_min-1, main_y_min)
 143       translate([0, top_base_z])
 144       scale([1, strain_groove_d/strain_groove_w])
 145       circle(strain_groove_w/2, $fn = 8);
 146   }
 147 }
 148
 149 module TopElevationForCutout(){
 150     rectfromto([ -(top_side_wall_x + side_x_gap), top_base_z ],
 151                [ +(top_side_wall_x + side_x_gap), top_top_z  ]);
 152 }
 153 module BottomMainElevation(){
 154   difference(){
 155     rectfromto([ -total_side_wall_x, bottom_base_z        ],
 156                [ +total_side_wall_x, bottom_wall_top_z    ]);
 157
 158     TopElevationForCutout();
 159   }
 160 }
 161 module Bottom(){ ////toplevel
 162   difference(){
 163     union(){
 164       linextr_y_xz(total_y_min, front_y_max)
 165         BottomMainElevation();
 166     }
 167
 168     linextr_y_xz(total_y_min + side_wall_th,
 169                  front_y_max - side_wall_th)
 170       rectfromto([ -board_w/2, bottom_base_z + bottom_floor_th ],
 171                  [ +board_w/2, 20         ]);
 172
 173     linextr_y_xz(total_y_min - 1,
 174                  total_y_min + side_wall_th + 1){
 175       translate([ 0, top_base_z ]){
 176         hull(){
 177           translate([ 0, -cable_dia/2 ])
 178             circle(r = cable_dia/2, $fa = 10, $fs = 1);
 179           square([ cable_dia, 0.1 ], center=true);
 180         }
 181       }
 182     }
 183   }
 184 }
 185
 186 module CoverMainElevation(){
 187   difference(){
 188     rectfromto([ -total_side_wall_x, cover_wall_bot_z        ],
 189                [ +total_side_wall_x, cover_top_z    ]);
 190
 191     TopElevationForCutout();
 192   }
 193 }
 194 module Cover(){ ////toplevel
 195   linextr_y_xz(main_y_min, front_y_max)
 196     CoverMainElevation();
 197 }
 198
 199 module BottomDemo(){ ////toplevel
 200   translate([0, 0, -0.25]) Bottom();
 201   %Top();
 202   translate([0, 0, +0.25]) Cover();
 203 }