1 lowres = 0; // fast rendering or fine printing with print-friendly orientation
6 wall = 1.5; // generic wall thickness
8 // 18650 is ~18mm diameter, ~65mm length,
15 front_flat_len = batt_len + 4*wall + 2*cable_sep;
17 // PCB-related dimensions
18 pcb_len = 36 + 1; // length of the board
19 pcb_width = 11 + 0.5; // width of the board
20 pcb_thick = 1.2 + 0.3; // thickness of the board
21 pcb_comp_h = 2.2; // height of the components on board
24 body_top_h = 0.35 * batt_diam; // cube-shaped part of the body
29 batt_end_h = wire_sep/2 + wire_thick/2 + 1.5;;
31 lid_sep = 0.2; // the lid is made this much smaller to separate from the body
35 sw_xoff = 250 * 25.4/1000; // x offset of microswitches
36 pcb_xoff = 90 * 25.4/1000; // offset of the LED from the middle of the PCB
38 prg_len = 10; // programming connector
44 // mounting cylinder + holes
47 mountcyl_w = mounthole_w + 4*wall;
49 mountcone_h = mounthole_h + 2*wall;
51 clip_pretension = 0.5;
53 plus_width = 4.5; // width of the + sign
57 translate([-batt_len/2-2*wall-cable_sep, -batt_diam/2-wall, 0])
58 cube([batt_len + 4*wall + 2*cable_sep,
59 batt_diam+2*wall, body_top_h]);
61 translate([-batt_len/2-2*wall-cable_sep, 0, 0])
63 cylinder(r=batt_diam/2+wall,
64 h = batt_len + 4*wall + 2*cable_sep);
65 translate([-infty/2, -infty/2, eps]) cube(infty);
67 translate([-front_flat_len/2,
68 batt_diam/2 - pcb_width,
69 -batt_diam/2-2*pcb_comp_h-pcb_thick-wall])
70 cube([front_flat_len, pcb_width+wall, eps]);
73 for (x = [-1, 1]) translate([x*(batt_len/2-mounthole_w/2),
74 batt_diam/2+wall, 0]) {
75 translate([0, 0, -batt_diam/2-wall-2*pcb_comp_h-pcb_thick])
77 translate([0, 0, body_top_h]) // rear
84 assign(h = mounthole_h+wall)
86 translate([0, -mountcyl_w/2+mounthole_h + wall])
87 cylinder(r = mountcyl_w/2, h = mountcyl_h);
88 assign(l = 2*sqrt(h*(mountcyl_w-h)))
89 translate([-l/2, 0, mountcyl_h + mountcone_h])
97 // upper cube-shaped part
99 translate([-batt_len/2, -batt_diam/2, 0])
100 cube([batt_len, batt_diam, batt_diam]);
102 // battery cylinder for the lower part
103 translate([-batt_len/2, 0, 0])
105 cylinder(r=batt_diam/2, h = batt_len);
108 translate([-pcb_len/2-pcb_xoff,
109 batt_diam/2-pcb_width,
110 -batt_diam/2-pcb_thick - pcb_comp_h])
111 cube([pcb_len, pcb_width,
112 batt_diam/2 + pcb_thick + pcb_comp_h + eps]);
113 // hole above the PCB for the outgoing cable
114 translate([-pcb_len/2-pcb_xoff-2*wall-outcable_w,
115 batt_diam/2-pcb_width,
116 -batt_diam/2-pcb_comp_h])
117 cube([pcb_len, pcb_width,
118 batt_diam/2 + pcb_comp_h + eps]);
120 translate([-pcb_xoff-pcb_len/2-wall-outcable_w,
121 -pcb_width+batt_diam/2,
122 -batt_diam/2-outcable_h])
123 cube([outcable_w, infty, outcable_h]);
124 // hole under the PCB
125 translate([-pcb_len/2+pcb_groove-pcb_xoff,
126 batt_diam/2-pcb_width + pcb_groove,
127 -batt_diam/2-pcb_thick - 2*pcb_comp_h])
128 cube([pcb_len-2*pcb_groove, pcb_width-2*pcb_groove,
129 batt_diam/2 + pcb_thick + pcb_comp_h + eps]);
130 // hole for prog connector
131 translate([pcb_len/2-pcb_xoff-pcb_groove-eps,
132 batt_diam/2-pcb_width/2-prg_width/2,
133 -batt_diam/2-pcb_thick - 2*pcb_comp_h])
135 cube([prg_len+pcb_groove+eps, prg_width,
136 batt_diam/2 + pcb_thick + pcb_comp_h + eps]);
137 translate([prg_len/2+pcb_groove, -eps, pcb_comp_h])
138 cube([prg_len/2+eps, prg_width+2*eps, pcb_thick]);
141 translate([0, batt_diam/2-pcb_width/2, -infty/2]) {
142 cylinder(r=led_diam/2, h=infty, $fn=6);
143 translate([sw_xoff, 0, 0])
144 cylinder(r=sw_diam/2, h=infty, $fn=6);
145 translate([-sw_xoff, 0, 0])
146 cylinder(r=sw_diam/2, h=infty, $fn=6);
148 // space under the wire holes for battery contacts
149 translate([-batt_len/2-2*wall-cable_sep-eps, 0, 0])
152 cylinder(r = batt_diam/2-wall, h = batt_len + 4*wall + 2*cable_sep + 2*eps);
153 translate([-infty/2, -infty/2, -batt_end_h])
156 // space above the wire holes for battery contacts
157 translate([-batt_len/2-2*wall-cable_sep-eps, -batt_diam/2, batt_end_h])
158 cube([batt_len + 4*wall + 2*cable_sep + 2*eps,
161 // wire holes for battery contacts
164 translate([-batt_len/2-wall-eps, x*wire_sep/2, y*wire_sep/2])
166 cylinder(r = wire_thick/2, h = batt_len + 2*wall + 2*eps, $fn=6);
167 // wire hole from PCB to battery contacts
168 // translate([-batt_len/2-wall-eps, 0, -batt_diam/2-pcb_comp_h + wire_thick/2])
170 translate([-batt_len/2-wall-eps, 0, -batt_diam/2 - wall/2 - wire_thick/2])
172 cylinder(r = wire_thick/2, h = batt_len + 2*wall + 2*eps, $fn=6);
173 // hole behind the battery contacts
175 scale([x, 1, 1]) translate([batt_len/2+wall+cable_sep, 0, 0]) hull() {
176 translate([0, -batt_diam/2, 0])
177 cube([wall + eps, batt_diam, infty]);
179 cylinder(r = batt_diam/2, h = wall+eps);
180 translate([0, batt_diam/2 - pcb_width,
181 -batt_diam/2-pcb_comp_h-pcb_thick])
182 cube([wall + eps, pcb_width, eps]);
183 translate([0, batt_diam/2 - pcb_width + 0.5*wall,
184 -batt_diam/2-2*pcb_comp_h-pcb_thick])
185 cube([wall + eps, pcb_width-0.5*wall, eps]);
187 // inner hole behind the battery contacts
189 scale([x, 1, 1]) translate([batt_len/2+wall, 0, 0]) hull() {
190 translate([0, -batt_diam/2+wall, 0])
191 cube([cable_sep + eps, batt_diam-2*wall, infty]);
193 cylinder(r = batt_diam/2-wall, h = cable_sep+eps);
195 // cable lead to battery contacts
196 for (x=[1, -1]) scale([x, 1, 1])
198 translate([batt_len/2-eps, -wire_thick/2, batt_diam/2-2.7])
199 cube([wall+cable_sep+2*eps, wire_thick, 5.4]);
202 for(x=[-1,1]) scale([x, 1, 1])
203 translate([batt_len/2-mounthole_w/2, batt_diam/2+wall+mounthole_h/2, -infty/2])
204 scale([1, mounthole_h/mounthole_w, 1])
205 cylinder(r = mounthole_w/2, h = infty);
207 for(x=[-1,1]) scale([x, 1, 1])
208 translate([batt_len/2+cable_sep+wall+10, batt_diam/2-pcb_width/2, -batt_diam/2-2*pcb_comp_h-pcb_thick-wall-eps])
209 cylinder(r1 = 10, r2 = 10 - wall, h = wall + 2*eps);
210 // plus sign - vertical line
211 translate([batt_len/2 - 1.5*wall-plus_width/2, -plus_width/2, -batt_diam/2-wall])
212 cube([wall, plus_width, infty]);
213 // plus and minus signs - horizontal line
214 for(x=[-1,1]) scale([x, 1, 1])
215 translate([batt_len/2 - wall - plus_width, -wall/2, -batt_diam/2-wall])
216 cube([plus_width, wall, infty]);
219 for (x = [-1, 1]) scale([x, 1, 1]) hull () {
220 translate([batt_len/2+wall+cable_sep-eps, batt_diam/2-pcb_width+wall/2+lid_sep,
221 -batt_diam/2-pcb_thick-pcb_comp_h + wall + lid_sep])
222 cube([wall+eps, pcb_width-2*wall-2*lid_sep, wall]);
223 translate([batt_len/2+wall+cable_sep-eps, batt_diam/2-pcb_width+3*wall/2+lid_sep,
224 -batt_diam/2-pcb_thick-pcb_comp_h + 3*wall + lid_sep])
225 cube([eps, pcb_width-4*wall-2*lid_sep, eps]);
230 translate([-batt_len/2 - wall - cable_sep - lid_sep, -batt_diam/2+lid_sep, -batt_diam/2 -wall])
231 cube([batt_len + 2*wall + 2*cable_sep + 2*lid_sep, batt_diam-2*lid_sep, batt_diam/2 - batt_end_h + wall - lid_sep]);
233 translate([-batt_len/2 - 2*wall - cable_sep,
234 -batt_diam/2, -batt_diam/2-wall])
235 cube([batt_len + 4*wall + 2*cable_sep,
237 translate([-batt_len/2 - 3*wall - cable_sep,
238 -batt_diam/2 - wall, -body_top_h-wall/2-lid_sep])
239 cube([batt_len + 6*wall + 2*cable_sep,
240 batt_diam + 2*wall, wall/2]);
242 // clip behind the battery contacts
244 scale([x, 1, 1]) translate([batt_len/2+wall+cable_sep+lid_sep, 0, 0]) hull() {
245 translate([0, -batt_diam/2+lid_sep, -batt_diam/2])
246 cube([wall-lid_sep, batt_diam-2*lid_sep, eps]);
248 cylinder(r = batt_diam/2-lid_sep, h = wall-lid_sep);
249 translate([-clip_pretension, batt_diam/2 - pcb_width + 0.5*wall + lid_sep,
250 batt_diam/2+2*pcb_comp_h+pcb_thick-lid_sep])
251 cube([wall+clip_pretension, pcb_width-0.5*wall-1.5*lid_sep, eps]);
253 // outer part of the clip behind the battery contacts
254 for (x=[1, -1]) scale([x, 1, 1]) translate([batt_len/2+2*wall+cable_sep+lid_sep, 0, 0]) hull() {
255 translate([0, -batt_diam/2 - wall, -body_top_h-wall/2-lid_sep])
256 cube([wall-lid_sep, batt_diam + 2*wall, wall/2]);
259 sphere(batt_diam/2+wall);
260 translate([-infty/2, -infty/2, -infty-body_top_h-lid_sep+2*wall])
262 translate([-infty-clip_pretension, -infty/2, -infty/2])
265 translate([-clip_pretension,
266 batt_diam/2 - pcb_width,
267 batt_diam/2+2*pcb_comp_h+pcb_thick+wall])
268 cube([wall-lid_sep, pcb_width+wall, eps]);
275 translate([-batt_len/2+eps, 0, 0]) rotate([0, 90, 0])
276 cylinder(r=batt_diam/2, h=batt_len-2*eps);
278 for (x = [-1, 1]) scale([x, 1, 1]) hull () {
279 translate([batt_len/2+wall+cable_sep-clip_pretension, batt_diam/2-pcb_width+wall/2,
280 batt_diam/2+pcb_thick+pcb_comp_h-2*wall])
281 cube([wall+clip_pretension+eps, pcb_width-2*wall, wall]);
282 translate([batt_len/2+wall+cable_sep-eps, batt_diam/2-pcb_width+wall/2,
283 batt_diam/2+pcb_thick+pcb_comp_h-4*wall + lid_sep])
284 cube([eps, pcb_width-2*wall, eps]);
289 translate([-batt_len/2-cable_sep-wall, 0, 0]) rotate([0, 90, 0])
290 cylinder(r=batt_diam/2-wall-lid_sep, h=batt_len+2*wall+2*cable_sep);
291 translate([-infty/2, -batt_diam/2, -infty-wire_sep/2-wire_thick/2])
292 cube([infty, batt_diam, infty]);
294 translate([-batt_len/2-cable_sep-wall, batt_diam/2-pcb_width+0.5*wall+0.5*lid_sep, batt_diam/2 + pcb_comp_h+pcb_thick-wall-lid_sep])
295 cube([batt_len + 2*wall + 2* cable_sep, pcb_width-1.5*wall-1.5*lid_sep, eps]);
302 translate([0, 15, 0]) case();
303 translate([0, -15, 0]) rotate([180, 0, 0]) lid();
305 translate([0, 15, batt_diam/2+pcb_thick+2*pcb_comp_h+wall])
307 translate([0, -15, batt_diam/2+wall])