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_groove = 1;
  23
  24 body_top_h = 0.35 * batt_diam; // cube-shaped part of the body
  25
  26 wire_thick = 2.2;
  27 wire_sep = 3.5;
  28
  29 batt_end_h = wire_sep/2 + wire_thick/2 + 1.5;;
  30
  31 lid_sep = 0.2; // the lid is made this much smaller to separate from the body
  32
  33 sw_diam = 2.5 + 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 module case_body() {
  54         hull() {
  55                 translate([-batt_len/2-2*wall-cable_sep, -batt_diam/2-wall, 0])
  56                         cube([batt_len + 4*wall + 2*cable_sep,
  57                                 batt_diam+2*wall, body_top_h]);
  58                 difference() {
  59                         translate([-batt_len/2-2*wall-cable_sep, 0, 0])
  60                                 rotate([0, 90, 0])
  61                                 cylinder(r=batt_diam/2+wall,
  62                                         h = batt_len + 4*wall + 2*cable_sep);
  63                         translate([-infty/2, -infty/2, eps]) cube(infty);
  64                 };
  65                 translate([-front_flat_len/2,
  66                         batt_diam/2 - pcb_width,
  67                         -batt_diam/2-2*pcb_comp_h-pcb_thick-wall])
  68                         cube([front_flat_len, pcb_width+wall, eps]);
  69         };
  70         // mounting cylinders
  71         for (x = [-1, 1]) translate([x*(batt_len/2-mounthole_w/2),
  72                 batt_diam/2+wall, 0]) {
  73                         translate([0, 0, -batt_diam/2-wall-2*pcb_comp_h-pcb_thick])
  74                                 mount_cyl(); // front
  75                         translate([0, 0, body_top_h]) // rear
  76                                 scale([1, 1, -1])
  77                                 mount_cyl();
  78         };
  79 };
  80
  81 module mount_cyl() {
  82         assign(h = mounthole_h+wall)
  83         hull () {
  84                 translate([0, -mountcyl_w/2+mounthole_h + wall])
  85                         cylinder(r = mountcyl_w/2, h = mountcyl_h);
  86                 assign(l = 2*sqrt(h*(mountcyl_w-h)))
  87                 translate([-l/2, 0, mountcyl_h + mountcone_h])
  88                         cube([l, eps, eps]);
  89         };
  90 };
  91
  92 module case() {
  93         difference() {
  94                 case_body();
  95                 // upper cube-shaped part
  96                 // rotate([20, 0, 0])
  97                 translate([-batt_len/2, -batt_diam/2, 0])
  98                         cube([batt_len, batt_diam, batt_diam]);
  99
 100                 // battery cylinder for the lower part
 101                 translate([-batt_len/2, 0, 0])
 102                         rotate([0, 90, 0])
 103                         cylinder(r=batt_diam/2, h = batt_len);
 104
 105                 // hole for PCB
 106                 translate([-pcb_len/2-pcb_xoff,
 107                         batt_diam/2-pcb_width,
 108                         -batt_diam/2-pcb_thick - pcb_comp_h])
 109                         cube([pcb_len, pcb_width,
 110                                 batt_diam/2 + pcb_thick + pcb_comp_h + eps]);
 111                 // hole above the PCB for the outgoing cable
 112                 translate([-pcb_len/2-pcb_xoff-2*wall-outcable_w,
 113                         batt_diam/2-pcb_width,
 114                         -batt_diam/2-pcb_comp_h])
 115                         cube([pcb_len, pcb_width,
 116                                 batt_diam/2 + pcb_comp_h + eps]);
 117                 // cable outlet
 118                 translate([-pcb_xoff-pcb_len/2-wall-outcable_w,
 119                         -pcb_width+batt_diam/2,
 120                         -batt_diam/2-outcable_h])
 121                         cube([outcable_w, infty, outcable_h]);
 122                 // hole under the PCB
 123                 translate([-pcb_len/2+pcb_groove-pcb_xoff,
 124                         batt_diam/2-pcb_width + pcb_groove,
 125                         -batt_diam/2-pcb_thick - 2*pcb_comp_h])
 126                         cube([pcb_len-2*pcb_groove, pcb_width-2*pcb_groove,
 127                                 batt_diam/2 + pcb_thick + pcb_comp_h + eps]);
 128                 // hole for prog connector
 129                 translate([pcb_len/2-pcb_xoff-pcb_groove-eps,
 130                         batt_diam/2-pcb_width/2-prg_width/2,
 131                         -batt_diam/2-pcb_thick - 2*pcb_comp_h])
 132                         difference() {
 133                                 cube([prg_len+pcb_groove+eps, prg_width,
 134                                         batt_diam/2 + pcb_thick + pcb_comp_h + eps]);
 135                                 translate([prg_len/2+pcb_groove, -eps, pcb_comp_h])
 136                                         cube([prg_len/2+eps, prg_width+2*eps, pcb_thick]);
 137                         };
 138                 // LED hole
 139                 translate([0, batt_diam/2-pcb_width/2, -infty/2]) {
 140                         cylinder(r=led_diam/2, h=infty, $fn=6);
 141                         translate([sw_xoff, 0, 0])
 142                                 cylinder(r=sw_diam/2, h=infty, $fn=6);
 143                         translate([-sw_xoff, 0, 0])
 144                                 cylinder(r=sw_diam/2, h=infty, $fn=6);
 145                 };
 146                 // space under the wire holes for battery contacts
 147                 translate([-batt_len/2-2*wall-cable_sep-eps, 0, 0])
 148                         difference() {
 149                                 rotate([0, 90, 0])
 150                                         cylinder(r = batt_diam/2-wall, h = batt_len + 4*wall + 2*cable_sep + 2*eps);
 151                                 translate([-infty/2, -infty/2, -batt_end_h])
 152                                         cube(infty);
 153                         };
 154                 // space above the wire holes for battery contacts
 155                 translate([-batt_len/2-2*wall-cable_sep-eps, -batt_diam/2, batt_end_h])
 156                         cube([batt_len + 4*wall + 2*cable_sep + 2*eps,
 157                                 batt_diam,
 158                                 batt_end_h]);
 159                 // wire holes for battery contacts
 160                 for (x = [-1, 1])
 161                 for (y = [-1, 1])
 162                         translate([-batt_len/2-wall-eps, x*wire_sep/2, y*wire_sep/2])
 163                         rotate([0, 90, 0])
 164                                 cylinder(r = wire_thick/2, h = batt_len + 2*wall + 2*eps, $fn=6);
 165                 // wire hole from PCB to battery contacts
 166                 // translate([-batt_len/2-wall-eps, 0, -batt_diam/2-pcb_comp_h + wire_thick/2])
 167                 rotate([40, 0, 0])
 168                 translate([-batt_len/2-wall-eps, 0, -batt_diam/2 - wall/2 - wire_thick/2])
 169                         rotate([0, 90, 0])
 170                                 cylinder(r = wire_thick/2, h = batt_len + 2*wall + 2*eps, $fn=6);
 171                 // hole behind the battery contacts
 172                 for(x=[1, -1])
 173                 scale([x, 1, 1]) translate([batt_len/2+wall+cable_sep, 0, 0]) hull() {
 174                         translate([0, -batt_diam/2, 0])
 175                                 cube([wall + eps, batt_diam, infty]);
 176                         rotate([0, 90, 0])
 177                                 cylinder(r = batt_diam/2, h = wall+eps);
 178                         translate([0, batt_diam/2 - pcb_width,
 179                                 -batt_diam/2-pcb_comp_h-pcb_thick])
 180                                 cube([wall + eps, pcb_width, eps]);
 181                         translate([0, batt_diam/2 - pcb_width + 0.5*wall,
 182                                 -batt_diam/2-2*pcb_comp_h-pcb_thick])
 183                                 cube([wall + eps, pcb_width-0.5*wall, eps]);
 184                 };
 185                 // inner hole behind the battery contacts
 186                 for(x=[1, -1])
 187                 scale([x, 1, 1]) translate([batt_len/2+wall, 0, 0]) hull() {
 188                         translate([0, -batt_diam/2+wall, 0])
 189                                 cube([cable_sep + eps, batt_diam-2*wall, infty]);
 190                         rotate([0, 90, 0])
 191                                 cylinder(r = batt_diam/2-wall, h = cable_sep+eps);
 192                 };
 193                 // cable lead to battery contacts
 194                 for (x=[1, -1]) scale([x, 1, 1])
 195                         rotate([-140, 0, 0])
 196                         translate([batt_len/2-eps, -wire_thick/2, batt_diam/2-2.7])
 197                                 cube([wall+cable_sep+2*eps, wire_thick, 5.4]);
 198
 199                 // mounting holes
 200                 for(x=[-1,1]) scale([x, 1, 1])
 201                 translate([batt_len/2-mounthole_w/2, batt_diam/2+wall+mounthole_h/2, -infty/2])
 202                         scale([1, mounthole_h/mounthole_w, 1])
 203                         cylinder(r = mounthole_w/2, h = infty);
 204                 // grabbing gap
 205                 for(x=[-1,1]) scale([x, 1, 1])
 206                 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])
 207                         cylinder(r1 = 10, r2 = 10 - wall, h = wall + 2*eps);
 208         };
 209         // clip barrier
 210         for (x = [-1, 1]) scale([x, 1, 1]) hull () {
 211                 translate([batt_len/2+wall+cable_sep-eps, batt_diam/2-pcb_width+wall/2+lid_sep,
 212                         -batt_diam/2-pcb_thick-pcb_comp_h + wall + lid_sep])
 213                         cube([wall+eps, pcb_width-2*wall-2*lid_sep, wall]);
 214                 translate([batt_len/2+wall+cable_sep-eps, batt_diam/2-pcb_width+3*wall/2+lid_sep,
 215                         -batt_diam/2-pcb_thick-pcb_comp_h + 3*wall + lid_sep])
 216                         cube([eps, pcb_width-4*wall-2*lid_sep, eps]);
 217         };
 218 };
 219
 220 module lid_body() {
 221         translate([-batt_len/2 - wall - cable_sep - lid_sep, -batt_diam/2+lid_sep, -batt_diam/2 -wall])
 222                 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]);
 223         hull () {
 224                 translate([-batt_len/2 - 2*wall - cable_sep,
 225                         -batt_diam/2, -batt_diam/2-wall])
 226                         cube([batt_len + 4*wall + 2*cable_sep,
 227                                 batt_diam, eps]);
 228                 translate([-batt_len/2 - 3*wall - cable_sep,
 229                         -batt_diam/2 - wall, -body_top_h-wall/2-lid_sep])
 230                         cube([batt_len + 6*wall + 2*cable_sep,
 231                                 batt_diam + 2*wall, wall/2]);
 232         };
 233         // clip behind the battery contacts
 234         for(x=[1, -1])
 235                 scale([x, 1, 1]) translate([batt_len/2+wall+cable_sep+lid_sep, 0, 0]) hull() {
 236                         translate([0, -batt_diam/2+lid_sep, -batt_diam/2])
 237                                 cube([wall-lid_sep, batt_diam-2*lid_sep, eps]);
 238                         rotate([0, 90, 0])
 239                                 cylinder(r = batt_diam/2-lid_sep, h = wall-lid_sep);
 240                         translate([-clip_pretension, batt_diam/2 - pcb_width + 0.5*wall + lid_sep,
 241                                 batt_diam/2+2*pcb_comp_h+pcb_thick-lid_sep])
 242                                 cube([wall+clip_pretension, pcb_width-0.5*wall-1.5*lid_sep, eps]);
 243                 };
 244         // outer part of the clip behind the battery contacts
 245         for (x=[1, -1]) scale([x, 1, 1]) translate([batt_len/2+2*wall+cable_sep+lid_sep, 0, 0]) hull() {
 246                 translate([0, -batt_diam/2 - wall, -body_top_h-wall/2-lid_sep])
 247                         cube([wall-lid_sep, batt_diam + 2*wall, wall/2]);
 248                 difference() {
 249                         scale([0.3, 1, 1])
 250                                 sphere(batt_diam/2+wall);
 251                         translate([-infty/2, -infty/2, -infty-body_top_h-lid_sep+2*wall])
 252                                 cube(infty);
 253                         translate([-infty-clip_pretension, -infty/2, -infty/2])
 254                                 cube(infty);
 255                 };
 256                 translate([-clip_pretension,
 257                         batt_diam/2 - pcb_width,
 258                         batt_diam/2+2*pcb_comp_h+pcb_thick+wall])
 259                         cube([wall-lid_sep, pcb_width+wall, eps]);
 260         };
 261 };
 262
 263 module lid() {
 264         difference() {
 265                 lid_body();
 266                 translate([-batt_len/2+eps, 0, 0]) rotate([0, 90, 0])
 267                         cylinder(r=batt_diam/2, h=batt_len-2*eps);
 268         // clip barrier
 269         for (x = [-1, 1]) scale([x, 1, 1]) hull () {
 270                 translate([batt_len/2+wall+cable_sep-clip_pretension, batt_diam/2-pcb_width+wall/2,
 271                         batt_diam/2+pcb_thick+pcb_comp_h-2*wall])
 272                         cube([wall+clip_pretension+eps, pcb_width-2*wall, wall]);
 273                 translate([batt_len/2+wall+cable_sep-eps, batt_diam/2-pcb_width+wall/2,
 274                         batt_diam/2+pcb_thick+pcb_comp_h-4*wall + lid_sep])
 275                         cube([eps, pcb_width-2*wall, eps]);
 276         };
 277 /*
 278                 hull() {
 279                         difference() {
 280                                 translate([-batt_len/2-cable_sep-wall, 0, 0]) rotate([0, 90, 0])
 281                                         cylinder(r=batt_diam/2-wall-lid_sep, h=batt_len+2*wall+2*cable_sep);
 282                                 translate([-infty/2, -batt_diam/2, -infty-wire_sep/2-wire_thick/2])
 283                                         cube([infty, batt_diam, infty]);
 284                         };
 285                         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])
 286                         cube([batt_len + 2*wall + 2* cable_sep, pcb_width-1.5*wall-1.5*lid_sep, eps]);
 287                 };
 288 */
 289         };
 290 };
 291
 292 if (lowres) {
 293         translate([0, 15, 0]) case();
 294         translate([0, -15, 0]) rotate([180, 0, 0]) lid();
 295 } else {
 296         translate([0, 15, batt_diam/2+pcb_thick+2*pcb_comp_h+wall])
 297                 case($fn=128);
 298         translate([0, -15, batt_diam/2+wall])
 299                 lid($fn=128);
 300 }
 301