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 + 0.6;
  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 rear_clip_hole_dist = 10; // distance between the holes in the rear clip
  44 rear_clip_aspect = 0.35; // w/h aspect ratio of the ellipse of the rear clip
  45
  46 module case_body() {
  47         hull() {
  48                 translate([-batt_len/2-2*wall-cable_sep, -batt_diam/2-wall, 0])
  49                         cube([batt_len + 4*wall + 2*cable_sep,
  50                                 batt_diam+2*wall, body_top_h]);
  51                 difference() {
  52                         translate([-batt_len/2-2*wall-cable_sep, 0, 0])
  53                                 rotate([0, 90, 0])
  54                                 cylinder(r=batt_diam/2+wall,
  55                                         h = batt_len + 4*wall + 2*cable_sep);
  56                         translate([-infty/2, -infty/2, eps]) cube(infty);
  57                 };
  58                 translate([-front_flat_len/2,
  59                         batt_diam/2 - pcb_width,
  60                         -batt_diam/2-2*pcb_comp_h-pcb_thick-wall])
  61                         cube([front_flat_len, pcb_width+wall, eps]);
  62         };
  63         for (x = [-1, 1]) scale([x, 1, 1]) hull() {
  64                 for (x0 = [0-wall, 10+wall])
  65                         translate([batt_len/2-wall-wire_thick-x0, batt_diam/2, 0])
  66                                 rotate([-90, 0, 0]) scale([rear_clip_aspect, 1, 1])
  67                                 cylinder(r=batt_diam/2 + 2*wall + wire_thick, h=wall);
  68                 };
  69 };
  70
  71 module case() {
  72         difference() {
  73                 case_body();
  74                 // upper cube-shaped part
  75                 // rotate([20, 0, 0])
  76                 translate([-batt_len/2, -batt_diam/2, 0])
  77                         cube([batt_len, batt_diam, batt_diam]);
  78
  79                 // battery cylinder for the lower part
  80                 translate([-batt_len/2, 0, 0])
  81                         rotate([0, 90, 0])
  82                         cylinder(r=batt_diam/2, h = batt_len);
  83
  84                 // hole for PCB
  85                 translate([-pcb_len/2-pcb_xoff,
  86                         batt_diam/2-pcb_width,
  87                         -batt_diam/2-pcb_thick - pcb_comp_h])
  88                         cube([pcb_len, pcb_width,
  89                                 batt_diam/2 + pcb_thick + pcb_comp_h + eps]);
  90                 // hole above the PCB
  91                 translate([-pcb_len/2-pcb_xoff-wall-2*outwire_thick,
  92                         batt_diam/2-pcb_width,
  93                         -batt_diam/2-pcb_comp_h])
  94                         cube([pcb_len, pcb_width,
  95                                 batt_diam/2 + pcb_comp_h + eps]);
  96                 // hole under the PCB
  97                 translate([-pcb_len/2+pcb_groove-pcb_xoff,
  98                         batt_diam/2-pcb_width + pcb_groove,
  99                         -batt_diam/2-pcb_thick - 2*pcb_comp_h])
 100                         cube([pcb_len-2*pcb_groove, pcb_width-2*pcb_groove,
 101                                 batt_diam/2 + pcb_thick + pcb_comp_h + eps]);
 102                 // hole for prog connector
 103                 translate([pcb_len/2-pcb_xoff-pcb_groove-eps,
 104                         batt_diam/2-pcb_width/2-prg_width/2,
 105                         -batt_diam/2-pcb_thick - 2*pcb_comp_h])
 106                         difference() {
 107                                 cube([prg_len+pcb_groove+eps, prg_width,
 108                                         batt_diam/2 + pcb_thick + pcb_comp_h + eps]);
 109                                 translate([prg_len/2+pcb_groove, -eps, pcb_comp_h])
 110                                         cube([prg_len/2+eps, prg_width+2*eps, pcb_thick]);
 111                         };
 112                 // LED hole
 113                 translate([0, batt_diam/2-pcb_width/2, -infty/2]) {
 114                         cylinder(r=led_diam/2, h=infty, $fn=6);
 115                         translate([sw_xoff, 0, 0])
 116                                 cylinder(r=sw_diam/2, h=infty, $fn=6);
 117                         translate([-sw_xoff, 0, 0])
 118                                 cylinder(r=sw_diam/2, h=infty, $fn=6);
 119                 };
 120                 // cable outlet
 121                 translate([-pcb_xoff-pcb_len/2-outwire_thick-wall, -6, 0])
 122                         rotate([40, 0, 0])
 123                         scale([2, 1, -1])
 124                         cylinder(r=outwire_thick/2, h = infty, $fn=12);
 125                 // space under the wire holes for battery contacts
 126                 translate([-batt_len/2-2*wall-cable_sep-eps, 0, 0])
 127                         difference() {
 128                                 rotate([0, 90, 0])
 129                                         cylinder(r = batt_diam/2-wall, h = batt_len + 4*wall + 2*cable_sep + 2*eps);
 130                                 translate([-infty/2, -infty/2, -batt_end_h])
 131                                         cube(infty);
 132                         };
 133                 // space above the wire holes for battery contacts
 134                 translate([-batt_len/2-2*wall-cable_sep-eps, -batt_diam/2, batt_end_h])
 135                         cube([batt_len + 4*wall + 2*cable_sep + 2*eps,
 136                                 batt_diam,
 137                                 batt_end_h]);
 138                 // wire holes for battery contacts
 139                 for (x = [-1, 1])
 140                 for (y = [-1, 1])
 141                         translate([-batt_len/2-wall-eps, x*wire_sep/2, y*wire_sep/2])
 142                         rotate([0, 90, 0])
 143                                 cylinder(r = wire_thick/2, h = batt_len + 2*wall + 2*eps, $fn=6);
 144                 // wire hole from PCB to battery contacts
 145                 // translate([-batt_len/2-wall-eps, 0, -batt_diam/2-pcb_comp_h + wire_thick/2])
 146                 rotate([40, 0, 0])
 147                 translate([-batt_len/2-wall-eps, 0, -batt_diam/2 - wall/2 - wire_thick/2])
 148                         rotate([0, 90, 0])
 149                                 cylinder(r = wire_thick/2, h = batt_len + 2*wall + 2*eps, $fn=6);
 150                 // hole behind the battery contacts
 151                 for(x=[1, -1])
 152                 scale([x, 1, 1]) translate([batt_len/2+wall, 0, 0]) hull() {
 153                         translate([0, -batt_diam/2, 0])
 154                                 cube([wall + cable_sep + eps, batt_diam, infty]);
 155                         rotate([0, 90, 0])
 156                                 cylinder(r = batt_diam/2, h = wall+cable_sep+eps);
 157                         translate([0, batt_diam/2 - pcb_width,
 158                                 -batt_diam/2-pcb_comp_h-pcb_thick])
 159                                 cube([wall + cable_sep + eps, pcb_width, eps]);
 160                         translate([cable_sep, batt_diam/2 - pcb_width + 1.5*wall,
 161                                 -batt_diam/2-pcb_comp_h-pcb_thick-wall])
 162                                 cube([wall + eps, pcb_width-2*wall, eps]);
 163                 };
 164                 // cable lead to battery contacts
 165                 for (x=[1, -1]) scale([x, 1, 1])
 166                         rotate([-140, 0, 0])
 167                         translate([batt_len/2+wire_thick/2, 0, batt_diam/2-2*wall])
 168                                 cylinder(r=wire_thick/2, h = 5);
 169
 170                 // mounting holes
 171                 for(x=[-1,1]) scale([x, 1, 1])
 172                 translate([batt_len/2-wall-wire_thick, batt_diam/2+2*wall, -batt_diam/2-pcb_thick-2*pcb_comp_h-wall])
 173                         vert_torus();
 174
 175                 for (x = [-1, 1]) scale([x, 1, 1]) for (x0 = [0, 10])
 176                         translate([batt_len/2-wall-wire_thick-x0, 0, batt_diam/2+wire_thick/2+wall])
 177                         rotate([-90, 0, 0])
 178                         scale([2,1,1]) cylinder (r=wire_thick/2, h=infty, $fn=16);
 179         };
 180         // clip barrier
 181         for (x = [-1, 1]) scale([x, 1, 1])
 182                 translate([batt_len/2+wall-eps, batt_diam/2-pcb_width+wall+lid_sep,
 183                         -batt_diam/2-pcb_thick-pcb_comp_h + wall + lid_sep])
 184                         cube([cable_sep+eps, pcb_width-2*wall-2*lid_sep, wall]);
 185 };
 186
 187 module lid_body() {
 188         translate([-batt_len/2 - wall - lid_sep, -batt_diam/2+lid_sep, -batt_diam/2 -wall])
 189                 cube([batt_len + 2*wall + 2*lid_sep, batt_diam-2*lid_sep, batt_diam/2 - batt_end_h + wall - lid_sep]);
 190         translate([-batt_len/2 - 2*wall - cable_sep, -batt_diam/2 - wall,
 191                 -batt_diam/2-wall])
 192                 cube([batt_len + 4*wall + 2*cable_sep, batt_diam + 2*wall,
 193                         wall + batt_diam/2 - body_top_h - lid_sep]);
 194         // clip behind the battery contacts
 195         for(x=[1, -1])
 196                 scale([x, 1, 1]) translate([batt_len/2+wall+lid_sep, 0, 0]) hull() {
 197                         translate([0, -batt_diam/2+lid_sep, -batt_diam/2])
 198                                 cube([wall+cable_sep-lid_sep, batt_diam-2*lid_sep, eps]);
 199                         rotate([0, 90, 0])
 200                                 cylinder(r = batt_diam/2-lid_sep, h = wall+cable_sep-lid_sep);
 201                         translate([0, batt_diam/2 - pcb_width+lid_sep,
 202                                 batt_diam/2+pcb_comp_h+pcb_thick-lid_sep])
 203                                 cube([wall+cable_sep-lid_sep, pcb_width-2*lid_sep, eps]);
 204                         translate([cable_sep+wall/2, batt_diam/2 - pcb_width + 1.5*wall +lid_sep,
 205                                 batt_diam/2+pcb_comp_h+pcb_thick+wall/2-lid_sep])
 206                                 cube([wall/2-lid_sep, pcb_width-2*wall-2*lid_sep, eps]);
 207                 };
 208 };
 209
 210 module lid() {
 211         difference() {
 212                 lid_body();
 213                 translate([-batt_len/2+eps, 0, 0]) rotate([0, 90, 0])
 214                         cylinder(r=batt_diam/2, h=batt_len-2*eps);
 215                 hull() {
 216                         difference() {
 217                                 translate([-batt_len/2-cable_sep-wall, 0, 0]) rotate([0, 90, 0])
 218                                         cylinder(r=batt_diam/2-wall-lid_sep, h=batt_len+2*wall+2*cable_sep);
 219                                 translate([-infty/2, -batt_diam/2, -infty-wire_sep/2-wire_thick/2])
 220                                         cube([infty, batt_diam, infty]);
 221                         };
 222                         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])
 223                         cube([batt_len + 2*wall + 2* cable_sep, pcb_width-1.5*wall-1.5*lid_sep, eps]);
 224                 };
 225                 // holes for the mounting clips on the body
 226                 for (x = [-1, 1]) scale([x, 1, 1]) hull() {
 227                 for (x0 = [0-wall, 10+wall])
 228                         translate([batt_len/2-wall-wire_thick-x0, batt_diam/2-lid_sep+eps, 0])
 229                                 rotate([-90, 0, 0]) scale([rear_clip_aspect, 1, 1])
 230                                 cylinder(r=batt_diam/2 + 2*wall + wire_thick+lid_sep/rear_clip_aspect, h=wall+lid_sep+eps);
 231                 };
 232         };
 233 };
 234
 235 module vert_torus() {
 236         rotate([0, 90, 0])
 237         scale([1, 1, 2])
 238         rotate_extrude() translate([5, 0, 0]) circle(r=wire_thick/2, $fn=16);
 239 };
 240
 241 if (lowres) {
 242         translate([0, 15, 0]) case();
 243         translate([0, -15, 0]) rotate([180, 0, 0]) lid();
 244 } else {
 245         translate([0, 15, batt_diam/2+pcb_thick+2*pcb_comp_h+wall])
 246                 case($fn=128);
 247         translate([0, -15, batt_diam/2+wall])
 248                 lid($fn=128);
 249 }
 250