case.scad

   1 lowres = 0;
   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 + 0.6;
  10 batt_len = 65 + 1.5;
  11
  12 cable_sep = 1;
  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_groove = 1;
  23
  24 body_top_h = 0.35 * batt_diam; // cube-shaped part of the body
  25
  26 outwire_thick = 2.2;
  27 wire_thick = 2.2;
  28 wire_sep = 3.5;
  29 cable_out_diam = 5.2;
  30
  31 batt_end_h = wire_sep/2 + wire_thick/2 + 1.5;;
  32
  33 lid_sep = 0.5; // the lid is made this much smaller to separate from the body
  34
  35 sw_diam = 2.5 + 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 module case_body() {
  44         hull() {
  45                 translate([-batt_len/2-2*wall-cable_sep, -batt_diam/2-wall, 0])
  46                         cube([batt_len + 4*wall + 2*cable_sep,
  47                                 batt_diam+2*wall, body_top_h]);
  48                 difference() {
  49                         translate([-batt_len/2-2*wall-cable_sep, 0, 0])
  50                                 rotate([0, 90, 0])
  51                                 cylinder(r=batt_diam/2+wall,
  52                                         h = batt_len + 4*wall + 2*cable_sep);
  53                         translate([-infty/2, -infty/2, eps]) cube(infty);
  54                 };
  55                 translate([-front_flat_len/2,
  56                         batt_diam/2 - pcb_width,
  57                         -batt_diam/2-2*pcb_comp_h-pcb_thick-wall])
  58                         cube([front_flat_len, pcb_width+wall, eps]);
  59         };
  60 };
  61
  62 module case() {
  63         difference() {
  64                 case_body();
  65                 // upper cube-shaped part
  66                 // rotate([20, 0, 0])
  67                 translate([-batt_len/2, -batt_diam/2, 0])
  68                         cube([batt_len, batt_diam, batt_diam]);
  69
  70                 // battery cylinder for the lower part
  71                 translate([-batt_len/2, 0, 0])
  72                         rotate([0, 90, 0])
  73                         cylinder(r=batt_diam/2, h = batt_len);
  74
  75                 // hole for PCB
  76                 translate([-pcb_len/2-pcb_xoff,
  77                         batt_diam/2-pcb_width,
  78                         -batt_diam/2-pcb_thick - pcb_comp_h])
  79                         cube([pcb_len, pcb_width,
  80                                 batt_diam/2 + pcb_thick + pcb_comp_h + eps]);
  81                 // hole above the PCB
  82                 translate([-pcb_len/2-pcb_xoff-wall-2*outwire_thick,
  83                         batt_diam/2-pcb_width,
  84                         -batt_diam/2-pcb_comp_h])
  85                         cube([pcb_len, pcb_width,
  86                                 batt_diam/2 + pcb_comp_h + eps]);
  87                 // hole under the PCB
  88                 translate([-pcb_len/2+pcb_groove-pcb_xoff,
  89                         batt_diam/2-pcb_width + pcb_groove,
  90                         -batt_diam/2-pcb_thick - 2*pcb_comp_h])
  91                         cube([pcb_len-2*pcb_groove, pcb_width-2*pcb_groove,
  92                                 batt_diam/2 + pcb_thick + pcb_comp_h + eps]);
  93                 // hole for prog connector
  94                 translate([pcb_len/2-pcb_xoff-pcb_groove-eps,
  95                         batt_diam/2-pcb_width/2-prg_width/2,
  96                         -batt_diam/2-pcb_thick - 2*pcb_comp_h])
  97                         difference() {
  98                                 cube([prg_len+pcb_groove+eps, prg_width,
  99                                         batt_diam/2 + pcb_thick + pcb_comp_h + eps]);
 100                                 translate([prg_len/2+pcb_groove, -eps, pcb_comp_h])
 101                                         cube([prg_len/2+eps, prg_width+2*eps, pcb_thick]);
 102                         };
 103                 // LED hole
 104                 translate([0, batt_diam/2-pcb_width/2, -infty/2]) {
 105                         cylinder(r=led_diam/2, h=infty, $fn=6);
 106                         translate([sw_xoff, 0, 0])
 107                                 cylinder(r=sw_diam/2, h=infty, $fn=6);
 108                         translate([-sw_xoff, 0, 0])
 109                                 cylinder(r=sw_diam/2, h=infty, $fn=6);
 110                 };
 111                 // cable outlet
 112                 translate([-pcb_xoff-pcb_len/2-outwire_thick-wall, -6, 0])
 113                         rotate([40, 0, 0])
 114                         scale([2, 1, -1])
 115                         cylinder(r=outwire_thick/2, h = infty, $fn=12);
 116                 // space under the wire holes for battery contacts
 117                 translate([-batt_len/2-2*wall-cable_sep-eps, 0, 0])
 118                         difference() {
 119                                 rotate([0, 90, 0])
 120                                         cylinder(r = batt_diam/2-wall, h = batt_len + 4*wall + 2*cable_sep + 2*eps);
 121                                 translate([-infty/2, -infty/2, -batt_end_h])
 122                                         cube(infty);
 123                         };
 124                 // space above the wire holes for battery contacts
 125                 translate([-batt_len/2-2*wall-cable_sep-eps, -batt_diam/2, batt_end_h])
 126                         cube([batt_len + 4*wall + 2*cable_sep + 2*eps,
 127                                 batt_diam,
 128                                 batt_end_h]);
 129                 // wire holes for battery contacts
 130                 for (x = [-1, 1])
 131                 for (y = [-1, 1])
 132                         translate([-batt_len/2-wall-eps, x*wire_sep/2, y*wire_sep/2])
 133                         rotate([0, 90, 0])
 134                                 cylinder(r = wire_thick/2, h = batt_len + 2*wall + 2*eps, $fn=6);
 135                 // wire hole from PCB to battery contacts
 136                 // translate([-batt_len/2-wall-eps, 0, -batt_diam/2-pcb_comp_h + wire_thick/2])
 137                 rotate([40, 0, 0])
 138                 translate([-batt_len/2-wall-eps, 0, -batt_diam/2 - wall/2 - wire_thick/2])
 139                         rotate([0, 90, 0])
 140                                 cylinder(r = wire_thick/2, h = batt_len + 2*wall + 2*eps, $fn=6);
 141                 // hole behind the battery contacts
 142                 for(x=[1, -1])
 143                 scale([x, 1, 1]) translate([batt_len/2+wall, 0, 0]) hull() {
 144                         translate([0, -batt_diam/2, 0])
 145                                 cube([wall + cable_sep + eps, batt_diam, infty]);
 146                         rotate([0, 90, 0])
 147                                 cylinder(r = batt_diam/2, h = wall+cable_sep+eps);
 148                         translate([0, batt_diam/2 - pcb_width,
 149                                 -batt_diam/2-pcb_comp_h-pcb_thick])
 150                                 cube([wall + cable_sep + eps, pcb_width, eps]);
 151                         translate([cable_sep, batt_diam/2 - pcb_width + 1.5*wall,
 152                                 -batt_diam/2-pcb_comp_h-pcb_thick-wall])
 153                                 cube([wall + eps, pcb_width-2*wall, eps]);
 154                 };
 155                 // cable lead to battery contacts
 156                 for (x=[1, -1]) scale([x, 1, 1])
 157                         rotate([-140, 0, 0])
 158                         translate([batt_len/2+wire_thick/2, 0, batt_diam/2-2*wall])
 159                                 cylinder(r=wire_thick/2, h = 5);
 160
 161                 // mounting holes
 162                 for(x=[-1,1]) scale([x, 1, 1])
 163                 translate([batt_len/2-wall-wire_thick, batt_diam/2+2*wall, -batt_diam/2-pcb_thick-2*pcb_comp_h-wall])
 164                         vert_torus();
 165
 166                 for (x = [-1, 1]) scale([x, 1, 1]) for (x0 = [0, 10])
 167                         translate([batt_len/2-wall-wire_thick-x0, 0, batt_end_h-wire_thick/2])
 168                         rotate([-90, 0, 0])
 169                         scale([2,1,1]) cylinder (r=wire_thick/2, h=infty, $fn=16);
 170         };
 171         // clip barrier
 172         for (x = [-1, 1]) scale([x, 1, 1])
 173                 translate([batt_len/2+wall-eps, batt_diam/2-pcb_width+wall+lid_sep,
 174                         -batt_diam/2-pcb_thick-pcb_comp_h + wall + lid_sep])
 175                         cube([cable_sep+eps, pcb_width-2*wall-2*lid_sep, wall]);
 176 };
 177
 178 module lid_body() {
 179         translate([-batt_len/2 - wall - lid_sep, -batt_diam/2+lid_sep, -batt_diam/2 -wall])
 180                 cube([batt_len + 2*wall + 2*lid_sep, batt_diam-2*lid_sep, batt_diam/2 - batt_end_h + wall - lid_sep]);
 181         translate([-batt_len/2 - 2*wall - cable_sep, -batt_diam/2 - wall,
 182                 -batt_diam/2-wall])
 183                 cube([batt_len + 4*wall + 2*cable_sep, batt_diam + 2*wall,
 184                         wall + batt_diam/2 - body_top_h - lid_sep]);
 185         // clip behind the battery contacts
 186         for(x=[1, -1])
 187                 scale([x, 1, 1]) translate([batt_len/2+wall+lid_sep, 0, 0]) hull() {
 188                         translate([0, -batt_diam/2+lid_sep, -batt_diam/2])
 189                                 cube([wall+cable_sep-lid_sep, batt_diam-2*lid_sep, eps]);
 190                         rotate([0, 90, 0])
 191                                 cylinder(r = batt_diam/2-lid_sep, h = wall+cable_sep-lid_sep);
 192                         translate([0, batt_diam/2 - pcb_width+lid_sep,
 193                                 batt_diam/2+pcb_comp_h+pcb_thick-lid_sep])
 194                                 cube([wall+cable_sep-lid_sep, pcb_width-2*lid_sep, eps]);
 195                         translate([cable_sep+wall/2, batt_diam/2 - pcb_width + 1.5*wall +lid_sep,
 196                                 batt_diam/2+pcb_comp_h+pcb_thick+wall/2-lid_sep])
 197                                 cube([wall/2-lid_sep, pcb_width-2*wall-2*lid_sep, eps]);
 198                 };
 199 };
 200
 201 module lid() {
 202         difference() {
 203                 lid_body();
 204                 translate([-batt_len/2+eps, 0, 0]) rotate([0, 90, 0])
 205                         cylinder(r=batt_diam/2, h=batt_len-2*eps);
 206                 hull() {
 207                         difference() {
 208                                 translate([-batt_len/2-cable_sep-wall, 0, 0]) rotate([0, 90, 0])
 209                                         cylinder(r=batt_diam/2-wall-lid_sep, h=batt_len+2*wall+2*cable_sep);
 210                                 translate([-infty/2, -batt_diam/2, -infty-wire_sep/2-wire_thick/2])
 211                                         cube([infty, batt_diam, infty]);
 212                         };
 213                         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])
 214                         cube([batt_len + 2*wall + 2* cable_sep, pcb_width-1.5*wall-1.5*lid_sep, eps]);
 215                 };
 216         };
 217 };
 218
 219 module vert_torus() {
 220         rotate([0, 90, 0])
 221         scale([1, 1, 2])
 222         rotate_extrude() translate([5, 0, 0]) circle(r=wire_thick/2, $fn=16);
 223 };
 224
 225 if (lowres) {
 226         translate([0, 15, 0]) case();
 227         translate([0, -15, 0]) rotate([180, 0, 0]) lid();
 228 } else {
 229         translate([0, 15, batt_diam/2+pcb_thick+2*pcb_comp_h+wall])
 230                 case($fn=128);
 231         translate([0, -15, batt_diam/2+wall])
 232                 lid($fn=128);
 233 }
 234