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 = 0.35 * batt_diam; // cube-shaped part of the body
  26
  27 wire_thick = 2.2;
  28 wire_sep = 3.5;
  29
  30 batt_end_h = wire_sep/2 + wire_thick/2 + 1.5;;
  31
  32 lid_sep = 0.2; // the lid is made this much smaller to separate from the body
  33
  34 // sw_diam = 2.5 + 0.5;
  35 sw_diam = 3.5 + 0.5;
  36 led_diam = 3 + 0.5;
  37 sw_xoff =  250 * 25.4/1000; // x offset of microswitches
  38 pcb_xoff = 90 * 25.4/1000; // offset of the LED from the middle of the PCB
  39
  40 prg_len = 10; // programming connector
  41 prg_width = 7;
  42
  43 outcable_h = 4.5;
  44 outcable_w = 2.5;
  45
  46 // mounting cylinder + holes
  47 mounthole_w = 5;
  48 mounthole_h = 3;
  49 mountcyl_w = mounthole_w + 4*wall;
  50 mountcyl_h = 2*wall;
  51 mountcone_h = mounthole_h + 2*wall;
  52
  53 clip_pretension = 0.5;
  54
  55 plus_width = 4.5; // width of the + sign
  56
  57 module case_body() {
  58         hull() {
  59                 translate([-batt_len/2-2*wall-cable_sep, -batt_diam/2-wall, 0])
  60                         cube([batt_len + 4*wall + 2*cable_sep,
  61                                 batt_diam+2*wall, body_top_h]);
  62                 difference() {
  63                         translate([-batt_len/2-2*wall-cable_sep, 0, 0])
  64                                 rotate([0, 90, 0])
  65                                 cylinder(r=batt_diam/2+wall,
  66                                         h = batt_len + 4*wall + 2*cable_sep);
  67                         translate([-infty/2, -infty/2, eps]) cube(infty);
  68                 };
  69                 translate([-front_flat_len/2,
  70                         batt_diam/2 - pcb_width,
  71                         -batt_diam/2-pcb_comp_h-pcb_comp_h2-pcb_thick-wall])
  72                         cube([front_flat_len, pcb_width+wall, eps]);
  73         };
  74         // mounting cylinders
  75         for (x = [-1, 1]) translate([x*(batt_len/2-mounthole_w/2),
  76                 batt_diam/2+wall, 0]) {
  77                         translate([0, 0, -batt_diam/2-wall-pcb_comp_h-pcb_comp_h2-pcb_thick])
  78                                 mount_cyl(); // front
  79                         translate([0, 0, body_top_h]) // rear
  80                                 scale([1, 1, -1])
  81                                 mount_cyl();
  82         };
  83 };
  84
  85 module mount_cyl() {
  86         assign(h = mounthole_h+wall)
  87         hull () {
  88                 translate([0, -mountcyl_w/2+mounthole_h + wall])
  89                         cylinder(r = mountcyl_w/2, h = mountcyl_h);
  90                 assign(l = 2*sqrt(h*(mountcyl_w-h)))
  91                 translate([-l/2, 0, mountcyl_h + mountcone_h])
  92                         cube([l, eps, eps]);
  93         };
  94 };
  95
  96 module case() {
  97         difference() {
  98                 case_body();
  99                 // upper cube-shaped part
 100                 // rotate([20, 0, 0])
 101                 translate([-batt_len/2, -batt_diam/2, 0])
 102                         cube([batt_len, batt_diam, batt_diam]);
 103
 104                 // battery cylinder for the lower part
 105                 translate([-batt_len/2, 0, 0])
 106                         rotate([0, 90, 0])
 107                         cylinder(r=batt_diam/2, h = batt_len);
 108
 109                 // hole for PCB
 110                 translate([-pcb_len/2-pcb_xoff,
 111                         batt_diam/2-pcb_width,
 112                         -batt_diam/2-pcb_thick - pcb_comp_h])
 113                         cube([pcb_len, pcb_width,
 114                                 batt_diam/2 + pcb_thick + pcb_comp_h + eps]);
 115                 // hole above the PCB for the outgoing cable
 116                 translate([-pcb_len/2-pcb_xoff-2*wall-outcable_w,
 117                         batt_diam/2-pcb_width,
 118                         -batt_diam/2-pcb_comp_h])
 119                         cube([pcb_len, pcb_width,
 120                                 batt_diam/2 + pcb_comp_h + eps]);
 121                 // cable outlet
 122                 translate([-pcb_xoff-pcb_len/2-wall-outcable_w,
 123                         -pcb_width+batt_diam/2,
 124                         -batt_diam/2-outcable_h])
 125                         cube([outcable_w, infty, outcable_h]);
 126                 // hole under the PCB (groove)
 127                 translate([-pcb_len/2+pcb_groove-pcb_xoff,
 128                         batt_diam/2-pcb_width + pcb_groove,
 129                         -batt_diam/2-pcb_thick - pcb_comp_h - pcb_comp_h2])
 130                         cube([pcb_len-2*pcb_groove, pcb_width-2*pcb_groove,
 131                                 batt_diam/2 + pcb_thick + pcb_comp_h2 + eps]);
 132                 // hole under the PCB (pcb-width)
 133                 translate([-pcb_len/2+2*pcb_groove-pcb_xoff,
 134                         batt_diam/2-pcb_width,
 135                         -batt_diam/2-pcb_thick - pcb_comp_h - pcb_comp_h2])
 136                         cube([pcb_len-4*pcb_groove, pcb_width,
 137                                 batt_diam/2 + pcb_thick + pcb_comp_h2 + eps]);
 138                 // hole for prog connector
 139                 translate([pcb_len/2-pcb_xoff-pcb_groove-eps,
 140                         batt_diam/2-pcb_width/2-prg_width/2,
 141                         -batt_diam/2-pcb_thick - pcb_comp_h - pcb_comp_h2])
 142                         difference() {
 143                                 cube([prg_len+pcb_groove+eps, prg_width,
 144                                         batt_diam/2 + pcb_thick + pcb_comp_h + eps]);
 145                                 translate([prg_len/2+pcb_groove, -eps, pcb_comp_h2])
 146                                         cube([prg_len/2+eps, prg_width+2*eps, pcb_thick]);
 147                         };
 148                 // LED and button holes
 149                 translate([0, batt_diam/2-pcb_width/2, -infty/2]) {
 150                         cylinder(r=led_diam/2, h=infty, $fn=6);
 151                         translate([sw_xoff, 0, 0])
 152                                 cylinder(r=sw_diam/2, h=infty, $fn=6);
 153                         translate([-sw_xoff, 0, 0])
 154                                 cylinder(r=sw_diam/2, h=infty, $fn=6);
 155                 };
 156                 // space under the wire holes for battery contacts
 157                 translate([-batt_len/2-2*wall-cable_sep-eps, 0, 0])
 158                         difference() {
 159                                 rotate([0, 90, 0])
 160                                         cylinder(r = batt_diam/2-wall, h = batt_len + 4*wall + 2*cable_sep + 2*eps);
 161                                 translate([-infty/2, -infty/2, -batt_end_h])
 162                                         cube(infty);
 163                         };
 164                 // space above the wire holes for battery contacts
 165                 translate([-batt_len/2-2*wall-cable_sep-eps, -batt_diam/2, batt_end_h])
 166                         cube([batt_len + 4*wall + 2*cable_sep + 2*eps,
 167                                 batt_diam,
 168                                 batt_end_h]);
 169                 // wire holes for battery contacts
 170                 for (x = [-1, 1])
 171                 for (y = [-1, 1])
 172                         translate([-batt_len/2-wall-eps, x*wire_sep/2, y*wire_sep/2])
 173                         rotate([0, 90, 0])
 174                                 cylinder(r = wire_thick/2, h = batt_len + 2*wall + 2*eps, $fn=6);
 175                 // wire hole from PCB to battery contacts
 176                 // translate([-batt_len/2-wall-eps, 0, -batt_diam/2-pcb_comp_h + wire_thick/2])
 177                 rotate([40, 0, 0])
 178                 translate([-batt_len/2-wall-eps, 0, -batt_diam/2 - wall/2 - wire_thick/2])
 179                         rotate([0, 90, 0])
 180                                 cylinder(r = wire_thick/2, h = batt_len + 2*wall + 2*eps, $fn=6);
 181                 // hole behind the battery contacts
 182                 for(x=[1, -1])
 183                 scale([x, 1, 1]) translate([batt_len/2+wall+cable_sep, 0, 0]) hull() {
 184                         translate([0, -batt_diam/2, 0])
 185                                 cube([wall + eps, batt_diam, infty]);
 186                         rotate([0, 90, 0])
 187                                 cylinder(r = batt_diam/2, h = wall+eps);
 188                         translate([0, batt_diam/2 - pcb_width,
 189                                 -batt_diam/2-pcb_comp_h-pcb_thick])
 190                                 cube([wall + eps, pcb_width, eps]);
 191                         translate([0, batt_diam/2 - pcb_width + 0.5*wall,
 192                                 -batt_diam/2-pcb_comp_h-pcb_comp_h2-pcb_thick])
 193                                 cube([wall + eps, pcb_width-0.5*wall, eps]);
 194                 };
 195                 // inner hole behind the battery contacts
 196                 for(x=[1, -1])
 197                 scale([x, 1, 1]) translate([batt_len/2+wall, 0, 0]) hull() {
 198                         translate([0, -batt_diam/2+wall, 0])
 199                                 cube([cable_sep + eps, batt_diam-2*wall, infty]);
 200                         rotate([0, 90, 0])
 201                                 cylinder(r = batt_diam/2-wall, h = cable_sep+eps);
 202                 };
 203                 // cable lead to battery contacts
 204                 for (x=[1, -1]) scale([x, 1, 1])
 205                         rotate([-140, 0, 0])
 206                         translate([batt_len/2-eps, -wire_thick/2, batt_diam/2-2.7])
 207                                 cube([wall+cable_sep+2*eps, wire_thick, 5.4]);
 208
 209                 // mounting holes
 210                 for(x=[-1,1]) scale([x, 1, 1])
 211                 translate([batt_len/2-mounthole_w/2, batt_diam/2+wall+mounthole_h/2, -infty/2])
 212                         scale([1, mounthole_h/mounthole_w, 1])
 213                         cylinder(r = mounthole_w/2, h = infty);
 214                 // grabbing gap
 215                 for(x=[-1,1]) scale([x, 1, 1])
 216                 translate([batt_len/2+cable_sep+wall+10, batt_diam/2-pcb_width/2, -batt_diam/2-pcb_comp_h-pcb_comp_h2-pcb_thick-wall-eps])
 217                         cylinder(r1 = 10, r2 = 10 - wall, h = wall + 2*eps);
 218                 // internal plus sign - vertical line
 219                 translate([-batt_len/2 + 0.5*wall+plus_width/2, -plus_width/2, -batt_diam/2-wall])
 220                         cube([wall, plus_width, infty]);
 221                 // internal plus and minus signs - horizontal line
 222                 for(x=[-1,1]) scale([x, 1, 1])
 223                 translate([batt_len/2 - wall - plus_width, -wall/2, -batt_diam/2-wall])
 224                         cube([plus_width, wall, infty]);
 225                 // button + label
 226                 scale([-1, 1, 1])
 227                 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])
 228                         cube([wall, plus_width, wall/2]);
 229                 // button +/- label - horizontal line
 230                 for (x=[-1, 1]) scale([x, 1, 1])
 231                 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])
 232                         cube([plus_width, wall, wall/2]);
 233         };
 234         // clip barrier
 235         for (x = [-1, 1]) scale([x, 1, 1]) hull () {
 236                 translate([batt_len/2+wall+cable_sep-eps, batt_diam/2-pcb_width+wall/2+lid_sep,
 237                         -batt_diam/2-pcb_thick-pcb_comp_h + wall + lid_sep])
 238                         cube([wall+eps, pcb_width-2*wall-2*lid_sep, wall]);
 239                 translate([batt_len/2+wall+cable_sep-eps, batt_diam/2-pcb_width+3*wall/2+lid_sep,
 240                         -batt_diam/2-pcb_thick-pcb_comp_h + 3*wall + lid_sep])
 241                         cube([eps, pcb_width-4*wall-2*lid_sep, eps]);
 242         };
 243 };
 244
 245 module lid_body() {
 246         translate([-batt_len/2 - wall - cable_sep - lid_sep, -batt_diam/2+lid_sep, -batt_diam/2 -wall])
 247                 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]);
 248         hull () {
 249                 translate([-batt_len/2 - 2*wall - cable_sep,
 250                         -batt_diam/2, -batt_diam/2-wall])
 251                         cube([batt_len + 4*wall + 2*cable_sep,
 252                                 batt_diam, eps]);
 253                 translate([-batt_len/2 - 3*wall - cable_sep,
 254                         -batt_diam/2 - wall, -body_top_h-wall/2-lid_sep])
 255                         cube([batt_len + 6*wall + 2*cable_sep,
 256                                 batt_diam + 2*wall, wall/2]);
 257         };
 258         // clip behind the battery contacts
 259         for(x=[1, -1])
 260                 scale([x, 1, 1]) translate([batt_len/2+wall+cable_sep+lid_sep, 0, 0]) hull() {
 261                         translate([0, -batt_diam/2+lid_sep, -batt_diam/2])
 262                                 cube([wall-lid_sep, batt_diam-2*lid_sep, eps]);
 263                         rotate([0, 90, 0])
 264                                 cylinder(r = batt_diam/2-lid_sep, h = wall-lid_sep);
 265                         translate([-clip_pretension, batt_diam/2 - pcb_width + 0.5*wall + lid_sep,
 266                                 batt_diam/2+pcb_comp_h+pcb_comp_h2+pcb_thick-lid_sep])
 267                                 cube([wall+clip_pretension, pcb_width-0.5*wall-1.5*lid_sep, eps]);
 268                 };
 269         // outer part of the clip behind the battery contacts
 270         for (x=[1, -1]) scale([x, 1, 1]) translate([batt_len/2+2*wall+cable_sep+lid_sep, 0, 0]) hull() {
 271                 translate([0, -batt_diam/2 - wall, -body_top_h-wall/2-lid_sep])
 272                         cube([wall-lid_sep, batt_diam + 2*wall, wall/2]);
 273                 difference() {
 274                         scale([0.3, 1, 1])
 275                                 sphere(batt_diam/2+wall);
 276                         translate([-infty/2, -infty/2, -infty-body_top_h-lid_sep+2*wall])
 277                                 cube(infty);
 278                         translate([-infty-clip_pretension, -infty/2, -infty/2])
 279                                 cube(infty);
 280                 };
 281                 translate([-clip_pretension,
 282                         batt_diam/2 - pcb_width,
 283                         batt_diam/2+pcb_comp_h+pcb_comp_h2+pcb_thick+wall])
 284                         cube([wall-lid_sep, pcb_width+wall, eps]);
 285         };
 286 };
 287
 288 module lid() {
 289         difference() {
 290                 lid_body();
 291                 translate([-batt_len/2+eps, 0, 0]) rotate([0, 90, 0])
 292                         cylinder(r=batt_diam/2, h=batt_len-2*eps);
 293         // clip barrier
 294         for (x = [-1, 1]) scale([x, 1, 1]) hull () {
 295                 translate([batt_len/2+wall+cable_sep-clip_pretension, batt_diam/2-pcb_width+wall/2,
 296                         batt_diam/2+pcb_thick+pcb_comp_h-2*wall])
 297                         cube([wall+clip_pretension+eps, pcb_width-2*wall, wall]);
 298                 translate([batt_len/2+wall+cable_sep-eps, batt_diam/2-pcb_width+wall/2,
 299                         batt_diam/2+pcb_thick+pcb_comp_h-4*wall + lid_sep])
 300                         cube([eps, pcb_width-2*wall, eps]);
 301         };
 302 /*
 303                 hull() {
 304                         difference() {
 305                                 translate([-batt_len/2-cable_sep-wall, 0, 0]) rotate([0, 90, 0])
 306                                         cylinder(r=batt_diam/2-wall-lid_sep, h=batt_len+2*wall+2*cable_sep);
 307                                 translate([-infty/2, -batt_diam/2, -infty-wire_sep/2-wire_thick/2])
 308                                         cube([infty, batt_diam, infty]);
 309                         };
 310                         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])
 311                         cube([batt_len + 2*wall + 2* cable_sep, pcb_width-1.5*wall-1.5*lid_sep, eps]);
 312                 };
 313 */
 314         };
 315 };
 316
 317 if (lowres) {
 318         translate([0, 15, 0]) case();
 319         translate([0, -15, 0]) rotate([180, 0, 0]) lid();
 320 } else {
 321         translate([0, 15, batt_diam/2+pcb_thick+pcb_comp_h+pcb_comp_h2+wall])
 322                 case($fn=128);
 323         translate([0, -15, batt_diam/2+wall])
 324                 lid($fn=128);
 325 }
 326