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;
  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 main_y_min = -board_l - side_wall_th;
  27 ceil_y_min = wall_y_min - 5;;
  28
  29 small_walls = [
  30                [ [0, 0], [-sw_to_edge, -1.0] ],
  31                [ [sw_to_edge-4.5, -4.5], [sw_to_edge, -5.7] ],
  32 //             [ [3.0, -11.72],              [sw_to_edge, -13.38] ],
  33                [ [-sw_to_edge+3.85, -14.90], [sw_to_edge, -13.38] ],
  34                ];
  35 chip_cutout = [[ -sw_to_edge + 4.20,    -3.75 ],
  36                [ -sw_to_edge + 11.95,  -11.90 ]];
  37
  38 strain_w = 2.0 + 0.5;
  39 strain_t = 1.0 + 0.5;
  40 strain_pitch_across = 5;
  41 strain_pitch_along = 10;
  42 strain_groove_d = 2;
  43 strain_groove_w = 3;
  44
  45 cable_space_z = 6;
  46 bottom_floor_th = 1.5;
  47
  48 fit_gap_z = 0.5;
  49 side_x_gap = 0.5;
  50
  51 cover_ceil_th = 0.425;
  52
  53 // calculated
  54
  55 top_top_z = usb_wall_h;
  56 top_base_z = -board_th;
  57 bottom_base_z = top_base_z - cable_space_z - bottom_floor_th;;
  58
  59 front_y_max = front_wall_th;
  60
  61 strain_0_y_c = main_y_min - strain_w/2;
  62 strain_1_y_c = strain_0_y_c - strain_pitch_along;
  63 total_y_min = strain_1_y_c - strain_w/2 - side_wall_th;
  64
  65 bottom_wall_top_z = (top_top_z + top_base_z) * 0.5 - fit_gap_z/2;
  66 cover_wall_bot_z  = (top_top_z + top_base_z) * 0.5 + fit_gap_z/2;
  67 cover_top_z  = top_top_z + cover_ceil_th;
  68
  69 top_side_wall_x = +board_w/2 + side_wall_th;
  70 total_side_wall_x = top_side_wall_x + side_wall_th + side_x_gap;
  71
  72 module BothSides(){
  73   for (m=[0,1]) {
  74     mirror([m,0]) {
  75       children();
  76     }
  77   }
  78 }
  79 module FrontWallsPlan(slop) {
  80   BothSides(){
  81     rectfromto([ -board_w/2 - side_wall_th,    0             ],
  82                [ -usb_w/2 - slop,              front_wall_th ]);
  83   }
  84 }
  85 module TopSmallWallsPlan() {
  86   for (m=[0,1]) {
  87     mirror([m,0]) {
  88       rectfromto([ -usb_w/2,              -0.01        ],
  89                  [ -usb_w/2 + usb_wall_w, usb_tongue_d ]);
  90     }
  91   }
  92   FrontWallsPlan(0);
  93   for (w=small_walls) {
  94     rectfromto(w[0], w[1]);
  95   }
  96 }
  97 module TopCeilPlan() {
  98   difference(){
  99     BothSides(){
 100       rectfromto([ -usb_w/2,              -0.01        ],
 101                  [ 0.1,                   usb_tongue_d ]);
 102       rectfromto([ -board_w/2 - side_wall_th, 0            ],
 103                  [ 0.1,                       ceil_y_min   ]);
 104     }
 105     rectfromto(chip_cutout[0], chip_cutout[1]);
 106   }
 107 }
 108 module TopMainWallsPlan() {
 109   BothSides(){
 110     rectfromto([ -board_w/2 - side_wall_th, 0          ],
 111                [ -board_w/2,                wall_y_min ]);
 112   }
 113   FrontWallsPlan(usb_tongue_w_slop);
 114   rectfromto([ -board_w/2 - side_wall_th + 0, -      board_l   ],
 115              [ +board_w/2 + side_wall_th,            total_y_min ]);
 116 }
 117
 118 module Top(){ ////toplevel
 119   difference(){
 120     union(){
 121       linextr(0, usb_wall_h)
 122         TopSmallWallsPlan();
 123       linextr(usb_wall_h - usb_ceil_th, usb_wall_h)
 124         TopCeilPlan();
 125       linextr(-board_th, usb_wall_h)
 126         TopMainWallsPlan();
 127     }
 128
 129     for (y_c = [strain_0_y_c, strain_1_y_c]) {
 130       for (x_c = [-1,+1] * strain_pitch_across/2) {
 131         translate([x_c, y_c, 0])
 132           linextr(-20, 20)
 133           square([ strain_t, strain_w ], center=true);
 134       }
 135     }
 136     linextr_y_xz(total_y_min-1, main_y_min)
 137       translate([0, top_base_z])
 138       scale([1, strain_groove_d/strain_groove_w])
 139       circle(strain_groove_w/2, $fn = 8);
 140   }
 141 }
 142
 143 module TopElevationForCutout(){
 144     rectfromto([ -(top_side_wall_x + side_x_gap), top_base_z ],
 145                [ +(top_side_wall_x + side_x_gap), top_top_z  ]);
 146 }
 147 module BottomMainElevation(){
 148   difference(){
 149     rectfromto([ -total_side_wall_x, bottom_base_z        ],
 150                [ +total_side_wall_x, bottom_wall_top_z    ]);
 151
 152     TopElevationForCutout();
 153     rectfromto([ -board_w/2, bottom_base_z + bottom_floor_th ],
 154                [ +board_w/2, 20         ]);
 155   }
 156 }
 157 module Bottom(){ ////toplevel
 158   linextr_y_xz(total_y_min, front_y_max)
 159     BottomMainElevation();
 160 }
 161
 162 module CoverMainElevation(){
 163   difference(){
 164     rectfromto([ -total_side_wall_x, cover_wall_bot_z        ],
 165                [ +total_side_wall_x, cover_top_z    ]);
 166
 167     TopElevationForCutout();
 168   }
 169 }
 170 module Cover(){ ////toplevel
 171   linextr_y_xz(main_y_min, front_y_max)
 172     CoverMainElevation();
 173 }
 174
 175 module BottomDemo(){ ////toplevel
 176   translate([0, 0, -0.25]) Bottom();
 177   %Top();
 178   translate([0, 0, +0.25]) Cover();
 179 }