case.scad

   1 lowres = 0; // fast rendering or fine printing with print-friendly orientation
   2
   3 eps = 0.01;
   4 infty = 300;
   5
   6 wall = 1.5; // generic wall thickness
   7
   8 // 18650 is ~18mm diameter, ~65mm length,
   9 batt_diam = 18 + 0.8;
  10 batt_len = 65 + 2.0;
  11
  12 cable_sep = 1.5;
  13
  14 // front flat area
  15 front_flat_len = batt_len + 4*wall + 2*cable_sep;
  16
  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
  22 pcb_comp_h2 = 4.5;      // height of the components on board - component side
  23 pcb_groove = 1;
  24
  25 body_top_h = 0.38 * batt_diam; // cube-shaped part of the body
  26
  27 wire_thick = 2.5;
  28 wire_sep = 3.5;
  29
  30 lid_sep = 0.2; // the lid is made this much smaller to separate from the body
  31
  32 // sw_diam = 2.5 + 0.5;
  33 sw_diam = 3.5 + 0.5;
  34 led_diam = 3 + 0.5;
  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
  37
  38 prg_len = 10; // programming connector
  39 prg_width = 7;
  40
  41 outcable_h = 4.5;
  42 outcable_w = 2.5;
  43
  44 // mounting cylinder + holes
  45 mounthole_w = 5;
  46 mounthole_h = 3;
  47 mountcyl_w = mounthole_w + 4*wall;
  48 mountcyl_h = 2*wall;
  49 mountcone_h = mounthole_h + 2*wall;
  50
  51 clip_pretension = 0.5;
  52
  53 plus_width = 4.5; // width of the + sign
  54
  55 batt_contact_w = 12;
  56 clip_cyl_r = 1;
  57 batt_end_h = body_top_h - 4*clip_cyl_r;;
  58
  59
  60 module case_body() {
  61         hull() {
  62                 translate([-batt_len/2-2*wall-cable_sep, -batt_diam/2-wall, 0])
  63                         cube([batt_len + 4*wall + 2*cable_sep,
  64                                 batt_diam+2*wall, body_top_h]);
  65                 difference() {
  66                         translate([-batt_len/2-2*wall-cable_sep, 0, 0])
  67                                 rotate([0, 90, 0])
  68                                 cylinder(r=batt_diam/2+wall,
  69                                         h = batt_len + 4*wall + 2*cable_sep);
  70                         translate([-infty/2, -infty/2, eps]) cube(infty);
  71                 };
  72                 translate([-front_flat_len/2,
  73                         batt_diam/2 - pcb_width,
  74                         -batt_diam/2-pcb_comp_h-pcb_comp_h2-pcb_thick-wall])
  75                         cube([front_flat_len, pcb_width+wall, eps]);
  76         };
  77         // mounting cylinders
  78         for (x = [-1, 1]) translate([x*(batt_len/2-mounthole_w/2),
  79                 batt_diam/2+wall, 0]) {
  80                         translate([0, 0, -batt_diam/2-wall-pcb_comp_h-pcb_comp_h2-pcb_thick])
  81                                 mount_cyl(); // front
  82                         translate([0, 0, body_top_h]) // rear
  83                                 scale([1, 1, -1])
  84                                 mount_cyl();
  85         };
  86 };
  87
  88 module mount_cyl() {
  89         assign(h = mounthole_h+wall)
  90         hull () {
  91                 translate([0, -mountcyl_w/2+mounthole_h + wall])
  92                         cylinder(r = mountcyl_w/2, h = mountcyl_h);
  93                 assign(l = 2*sqrt(h*(mountcyl_w-h)))
  94                 translate([-l/2, 0, mountcyl_h + mountcone_h])
  95                         cube([l, eps, eps]);
  96         };
  97 };
  98
  99 module case() {
 100         difference() {
 101                 case_body();
 102                 // upper cube-shaped part
 103                 // rotate([20, 0, 0])
 104                 translate([-batt_len/2, -batt_diam/2, 0])
 105                         cube([batt_len, batt_diam, batt_diam]);
 106                 // upper longer cube-shaped part
 107                 difference() {
 108                         translate([-batt_len/2-cable_sep-wall, -batt_diam/2, batt_end_h])
 109                                 cube([batt_len+2*cable_sep+2*wall, batt_diam, batt_diam]);
 110                         for (x = [-1,1]) scale([x, 1, 1])
 111                                 translate([batt_len/2 + wall + cable_sep, -infty/2, batt_end_h + 3*clip_cyl_r])
 112                                 rotate([-90, 0, 0])
 113                                 cylinder(r = clip_cyl_r, h = infty, $fn=4);
 114                 }
 115                 // grabbing holes
 116                 for (x=[-1,1]) scale([x,1,1])
 117                 translate([batt_len/2 + 2*wall + cable_sep+10-wall, 0, 0])
 118                         cylinder(r1 = 7, r2 = 10-wall/4, h = body_top_h + eps);
 119                 // battery cylinder for the lower part
 120                 translate([-batt_len/2, 0, 0])
 121                         rotate([0, 90, 0])
 122                         cylinder(r=batt_diam/2, h = batt_len);
 123
 124                 // hole for PCB
 125                 translate([-pcb_len/2-pcb_xoff,
 126                         batt_diam/2-pcb_width,
 127                         -batt_diam/2-pcb_thick - pcb_comp_h])
 128                         cube([pcb_len, pcb_width,
 129                                 batt_diam/2 + pcb_thick + pcb_comp_h + eps]);
 130                 // hole above the PCB for the outgoing cable
 131                 translate([-pcb_len/2-pcb_xoff-2*wall-outcable_w,
 132                         batt_diam/2-pcb_width,
 133                         -batt_diam/2-pcb_comp_h])
 134                         cube([pcb_len, pcb_width,
 135                                 batt_diam/2 + pcb_comp_h + eps]);
 136                 // cable outlet
 137                 translate([-pcb_xoff-pcb_len/2-wall-outcable_w,
 138                         -pcb_width+batt_diam/2,
 139                         -batt_diam/2-outcable_h])
 140                         cube([outcable_w, infty, outcable_h]);
 141                 // hole under the PCB (groove)
 142                 translate([-pcb_len/2+pcb_groove-pcb_xoff,
 143                         batt_diam/2-pcb_width + pcb_groove,
 144                         -batt_diam/2-pcb_thick - pcb_comp_h - pcb_comp_h2])
 145                         cube([pcb_len-2*pcb_groove, pcb_width-2*pcb_groove,
 146                                 batt_diam/2 + pcb_thick + pcb_comp_h2 + eps]);
 147                 // hole under the PCB (pcb-width)
 148                 translate([-pcb_len/2+2*pcb_groove-pcb_xoff,
 149                         batt_diam/2-pcb_width,
 150                         -batt_diam/2-pcb_thick - pcb_comp_h - pcb_comp_h2])
 151                         cube([pcb_len-4*pcb_groove, pcb_width,
 152                                 batt_diam/2 + pcb_thick + pcb_comp_h2 + eps]);
 153                 // hole for prog connector
 154                 translate([pcb_len/2-pcb_xoff-pcb_groove-eps,
 155                         batt_diam/2-pcb_width/2-prg_width/2,
 156                         -batt_diam/2-pcb_thick - pcb_comp_h - pcb_comp_h2])
 157                         difference() {
 158                                 cube([prg_len+pcb_groove+eps, prg_width,
 159                                         batt_diam/2 + pcb_thick + pcb_comp_h + eps]);
 160                                 translate([prg_len/2+pcb_groove, -eps, pcb_comp_h2])
 161                                         cube([prg_len/2+eps, prg_width+2*eps, pcb_thick]);
 162                         };
 163                 // LED and button holes
 164                 translate([0, batt_diam/2-pcb_width/2, -infty/2]) {
 165                         cylinder(r=led_diam/2, h=infty, $fn=6);
 166                         translate([sw_xoff, 0, 0])
 167                                 cylinder(r=sw_diam/2, h=infty, $fn=6);
 168                         translate([-sw_xoff, 0, 0])
 169                                 cylinder(r=sw_diam/2, h=infty, $fn=6);
 170                 };
 171                 // wire hole from PCB to battery contacts
 172                 rotate([-48, 0, 0])
 173                 translate([-batt_len/2-wall-cable_sep, 0, -wire_thick/2-wall/2])
 174                         cube([batt_len + 2*wall + 2* cable_sep, batt_diam/2 + wire_thick + wall, wire_thick]);
 175                 // mounting holes
 176                 for(x=[-1,1]) scale([x, 1, 1])
 177                 translate([batt_len/2-mounthole_w/2, batt_diam/2+wall+mounthole_h/2, -infty/2])
 178                         scale([1, mounthole_h/mounthole_w, 1])
 179                         cylinder(r = mounthole_w/2, h = infty);
 180                 // holes in front of battery contacts
 181                 for(x=[-1,1]) scale([x, 1, 1])
 182                 translate([batt_len/2-eps, wall/2-batt_contact_w/2,
 183                         wall/2-batt_contact_w/2])
 184                         cube([wall+2*eps, batt_contact_w-wall, infty]);
 185                 // holes for battery contacts
 186                 for(x=[-1,1]) scale([x, 1, 1])
 187                 translate([batt_len/2+wall-eps, -batt_contact_w/2,
 188                         -batt_contact_w/2])
 189                         cube([cable_sep+2*eps, batt_contact_w, infty]);
 190                 // internal plus sign - vertical line
 191                 translate([-batt_len/2 + 0.5*wall+plus_width/2, -plus_width/2, -batt_diam/2-wall])
 192                         cube([wall, plus_width, infty]);
 193                 // internal plus and minus signs - horizontal line
 194                 for(x=[-1,1]) scale([x, 1, 1])
 195                 translate([batt_len/2 - wall - plus_width, -wall/2, -batt_diam/2-wall])
 196                         cube([plus_width, wall, infty]);
 197                 // button + label
 198                 scale([-1, 1, 1])
 199                 translate([sw_xoff + sw_diam/2 + wall/2 + plus_width/2, batt_diam/2-pcb_width/2-plus_width/2, -batt_diam/2-pcb_thick-pcb_comp_h-pcb_comp_h2-wall-eps])
 200                         cube([wall, plus_width, wall/2]);
 201                 // button +/- label - horizontal line
 202                 for (x=[-1, 1]) scale([x, 1, 1])
 203                 translate([sw_xoff + sw_diam/2 + wall, batt_diam/2-pcb_width/2-wall/2, -batt_diam/2-pcb_thick-pcb_comp_h-pcb_comp_h2-wall-eps])
 204                         cube([plus_width, wall, wall/2]);
 205         };
 206 };
 207
 208 module lid_body() {
 209         // outer part
 210         hull() {
 211                 // smaller outermost part
 212                 translate([-batt_len/2 - wall - cable_sep, -batt_diam/2, -batt_diam/2 - wall])
 213                         cube([batt_len + 2*wall + 2*cable_sep, batt_diam, eps]);
 214                 // this part goes above the main body
 215                 translate([-batt_len/2 - 2*wall - cable_sep, -batt_diam/2-wall, -body_top_h - lid_sep])
 216                         cube([batt_len + 4*wall + 2*cable_sep, batt_diam+2*wall, eps]);
 217         };
 218         // the part which goes inside the main body
 219         translate([-batt_len/2 - wall - cable_sep + lid_sep, -batt_diam/2+lid_sep, -batt_diam/2 -wall])
 220                 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]);
 221         // clips
 222         for (x = [-1, 1]) scale([x, 1, 1])
 223         translate([batt_len/2 + wall + cable_sep - lid_sep, batt_diam/2 - lid_sep, -batt_end_h-lid_sep-clip_cyl_r])
 224                 rotate([90, 0, 0])
 225                 cylinder(r = clip_cyl_r, h = batt_diam-2*lid_sep, $fn = 4);
 226 }
 227
 228 module lid() {
 229         difference() {
 230                 lid_body();
 231                 translate([-batt_len/2-lid_sep, 0, 0]) rotate([0, 90, 0])
 232                         cylinder(r=batt_diam/2 + lid_sep, h=batt_len+2*lid_sep);
 233         };
 234 };
 235
 236 if (lowres) {
 237         translate([0, 15, 0]) case();
 238         translate([0, -15, 0]) rotate([180, 0, 0]) lid();
 239 } else {
 240         translate([0, 15, batt_diam/2+pcb_thick+pcb_comp_h+pcb_comp_h2+wall])
 241                 case($fn=128);
 242         translate([0, -15, batt_diam/2+wall])
 243                 lid($fn=128);
 244 }
 245