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 plus_width = 4.5; // width of the + sign
  54
  55 module case_body() {
  56         hull() {
  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]);
  60                 difference() {
  61                         translate([-batt_len/2-2*wall-cable_sep, 0, 0])
  62                                 rotate([0, 90, 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);
  66                 };
  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]);
  71         };
  72         // mounting cylinders
  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])
  76                                 mount_cyl(); // front
  77                         translate([0, 0, body_top_h]) // rear
  78                                 scale([1, 1, -1])
  79                                 mount_cyl();
  80         };
  81 };
  82
  83 module mount_cyl() {
  84         assign(h = mounthole_h+wall)
  85         hull () {
  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])
  90                         cube([l, eps, eps]);
  91         };
  92 };
  93
  94 module case() {
  95         difference() {
  96                 case_body();
  97                 // upper cube-shaped part
  98                 // rotate([20, 0, 0])
  99                 translate([-batt_len/2, -batt_diam/2, 0])
 100                         cube([batt_len, batt_diam, batt_diam]);
 101
 102                 // battery cylinder for the lower part
 103                 translate([-batt_len/2, 0, 0])
 104                         rotate([0, 90, 0])
 105                         cylinder(r=batt_diam/2, h = batt_len);
 106
 107                 // hole for PCB
 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]);
 119                 // cable outlet
 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])
 134                         difference() {
 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]);
 139                         };
 140                 // LED hole
 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);
 147                 };
 148                 // space under the wire holes for battery contacts
 149                 translate([-batt_len/2-2*wall-cable_sep-eps, 0, 0])
 150                         difference() {
 151                                 rotate([0, 90, 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])
 154                                         cube(infty);
 155                         };
 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,
 159                                 batt_diam,
 160                                 batt_end_h]);
 161                 // wire holes for battery contacts
 162                 for (x = [-1, 1])
 163                 for (y = [-1, 1])
 164                         translate([-batt_len/2-wall-eps, x*wire_sep/2, y*wire_sep/2])
 165                         rotate([0, 90, 0])
 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])
 169                 rotate([40, 0, 0])
 170                 translate([-batt_len/2-wall-eps, 0, -batt_diam/2 - wall/2 - wire_thick/2])
 171                         rotate([0, 90, 0])
 172                                 cylinder(r = wire_thick/2, h = batt_len + 2*wall + 2*eps, $fn=6);
 173                 // hole behind the battery contacts
 174                 for(x=[1, -1])
 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]);
 178                         rotate([0, 90, 0])
 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]);
 186                 };
 187                 // inner hole behind the battery contacts
 188                 for(x=[1, -1])
 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]);
 192                         rotate([0, 90, 0])
 193                                 cylinder(r = batt_diam/2-wall, h = cable_sep+eps);
 194                 };
 195                 // cable lead to battery contacts
 196                 for (x=[1, -1]) scale([x, 1, 1])
 197                         rotate([-140, 0, 0])
 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]);
 200
 201                 // mounting holes
 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);
 206                 // grabbing gap
 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]);
 217         };
 218         // clip barrier
 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]);
 226         };
 227 };
 228
 229 module lid_body() {
 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]);
 232         hull () {
 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,
 236                                 batt_diam, eps]);
 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]);
 241         };
 242         // clip behind the battery contacts
 243         for(x=[1, -1])
 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]);
 247                         rotate([0, 90, 0])
 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]);
 252                 };
 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]);
 257                 difference() {
 258                         scale([0.3, 1, 1])
 259                                 sphere(batt_diam/2+wall);
 260                         translate([-infty/2, -infty/2, -infty-body_top_h-lid_sep+2*wall])
 261                                 cube(infty);
 262                         translate([-infty-clip_pretension, -infty/2, -infty/2])
 263                                 cube(infty);
 264                 };
 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]);
 269         };
 270 };
 271
 272 module lid() {
 273         difference() {
 274                 lid_body();
 275                 translate([-batt_len/2+eps, 0, 0]) rotate([0, 90, 0])
 276                         cylinder(r=batt_diam/2, h=batt_len-2*eps);
 277         // clip barrier
 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]);
 285         };
 286 /*
 287                 hull() {
 288                         difference() {
 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]);
 293                         };
 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]);
 296                 };
 297 */
 298         };
 299 };
 300
 301 if (lowres) {
 302         translate([0, 15, 0]) case();
 303         translate([0, -15, 0]) rotate([180, 0, 0]) lid();
 304 } else {
 305         translate([0, 15, batt_diam/2+pcb_thick+2*pcb_comp_h+wall])
 306                 case($fn=128);
 307         translate([0, -15, batt_diam/2+wall])
 308                 lid($fn=128);
 309 }
 310