lowres = 0; // fast rendering or fine printing with print-friendly orientation eps = 0.01; infty = 300; wall = 1.5; // generic wall thickness // 18650 is ~18mm diameter, ~65mm length, batt_diam = 18 + 0.8; batt_len = 65 + 2.0; cable_sep = 1.5; // front flat area front_flat_len = batt_len + 4*wall + 2*cable_sep; // PCB-related dimensions pcb_len = 36 + 1; // length of the board pcb_width = 11 + 0.5; // width of the board pcb_thick = 1.2 + 0.3; // thickness of the board pcb_comp_h = 2.2; // height of the components on board pcb_comp_h2 = 4.5; // height of the components on board - component side pcb_groove = 1; body_top_h = 0.38 * batt_diam; // cube-shaped part of the body wire_thick = 2.5; wire_sep = 3.5; lid_sep = 0.2; // the lid is made this much smaller to separate from the body // sw_diam = 2.5 + 0.5; sw_diam = 3.5 + 0.5; led_diam = 3 + 0.5; sw_xoff = 250 * 25.4/1000; // x offset of microswitches pcb_xoff = 90 * 25.4/1000; // offset of the LED from the middle of the PCB prg_len = 10; // programming connector prg_width = 7; outcable_h = 4.5; outcable_w = 2.5; // mounting cylinder + holes mounthole_w = 5; mounthole_h = 3; mountcyl_w = mounthole_w + 4*wall; mountcyl_h = 2*wall; mountcone_h = mounthole_h + 2*wall; clip_pretension = 0.5; plus_width = 4.5; // width of the + sign batt_contact_w = 12; batt_contact_h = 14; batt_contact_h_lid = batt_contact_h-2; clip_cyl_r = 0.7; batt_end_h = body_top_h - 4*clip_cyl_r;; module case_body() { hull() { translate([-batt_len/2-2*wall-cable_sep, -batt_diam/2-wall, 0]) cube([batt_len + 4*wall + 2*cable_sep, batt_diam+2*wall, body_top_h]); difference() { translate([-batt_len/2-2*wall-cable_sep, 0, 0]) rotate([0, 90, 0]) cylinder(r=batt_diam/2+wall, h = batt_len + 4*wall + 2*cable_sep); translate([-infty/2, -infty/2, eps]) cube(infty); }; translate([-front_flat_len/2, batt_diam/2 - pcb_width-0.5*wall, -batt_diam/2-pcb_comp_h-pcb_comp_h2-pcb_thick-wall]) cube([front_flat_len, pcb_width+1.5*wall, eps]); }; // mounting cylinders for (x = [-1, 1]) translate([x*(batt_len/2-mounthole_w/2), batt_diam/2+wall, 0]) { translate([0, 0, -batt_diam/2-wall-pcb_comp_h-pcb_comp_h2-pcb_thick]) mount_cyl(); // front translate([0, 0, body_top_h]) // rear scale([1, 1, -1]) mount_cyl(); }; }; module mount_cyl() { assign(h = mounthole_h+wall) hull () { translate([0, -mountcyl_w/2+mounthole_h + wall]) cylinder(r = mountcyl_w/2, h = mountcyl_h); assign(l = 2*sqrt(h*(mountcyl_w-h))) translate([-l/2, 0, mountcyl_h + mountcone_h]) cube([l, eps, eps]); }; }; module case() { difference() { case_body(); // upper cube-shaped part // rotate([20, 0, 0]) translate([-batt_len/2, -batt_diam/2, 0]) cube([batt_len, batt_diam, batt_end_h+eps]); // upper longer cube-shaped part difference() { translate([-batt_len/2-cable_sep-wall, -batt_diam/2, batt_end_h]) cube([batt_len+2*cable_sep+2*wall, batt_diam, batt_diam]); // clips for (x = [-1,1]) scale([1, x, 1]) translate([batt_len/6, batt_diam/2, batt_end_h + 3*clip_cyl_r]) rotate([0, -90, 0]) cylinder(r = clip_cyl_r, h = batt_len/3, $fn=4); } // grabbing holes for (x=[-1,1]) scale([x,1,1]) translate([batt_len/2 + 2*wall + cable_sep+10-wall, 0, 0]) cylinder(r1 = 7, r2 = 10, h = body_top_h + eps); // battery cylinder for the lower part translate([-batt_len/2, 0, 0]) rotate([0, 90, 0]) cylinder(r=batt_diam/2, h = batt_len); // hole for PCB translate([-pcb_len/2-pcb_xoff, batt_diam/2-pcb_width, -batt_diam/2-pcb_thick - pcb_comp_h]) cube([pcb_len, pcb_width, batt_diam/2 + pcb_thick + pcb_comp_h + eps]); // hole above the PCB for the outgoing cable translate([-pcb_len/2-pcb_xoff-2*wall-outcable_w, batt_diam/2-pcb_width, -batt_diam/2-pcb_comp_h]) cube([pcb_len, pcb_width, batt_diam/2 + pcb_comp_h + eps]); // cable outlet translate([-pcb_xoff-pcb_len/2-wall-outcable_w, -pcb_width+batt_diam/2, -batt_diam/2-outcable_h]) cube([outcable_w, infty, outcable_h]); // hole under the PCB (groove) translate([-pcb_len/2+pcb_groove-pcb_xoff, batt_diam/2-pcb_width + pcb_groove, -batt_diam/2-pcb_thick - pcb_comp_h - pcb_comp_h2]) cube([pcb_len-2*pcb_groove, pcb_width-2*pcb_groove, batt_diam/2 + pcb_thick + pcb_comp_h2 + eps]); // hole under the PCB (pcb-width) translate([-pcb_len/2+2*pcb_groove-pcb_xoff, batt_diam/2-pcb_width, -batt_diam/2-pcb_thick - pcb_comp_h - pcb_comp_h2]) cube([pcb_len-4*pcb_groove, pcb_width, batt_diam/2 + pcb_thick + pcb_comp_h2 + eps]); // hole for prog connector translate([pcb_len/2-pcb_xoff-pcb_groove-eps, batt_diam/2-pcb_width/2-prg_width/2, -batt_diam/2-pcb_thick - pcb_comp_h - pcb_comp_h2]) difference() { cube([prg_len+pcb_groove+eps, prg_width, batt_diam/2 + pcb_thick + pcb_comp_h + eps]); translate([prg_len/2+pcb_groove, -eps, pcb_comp_h2]) cube([prg_len/2+eps, prg_width+2*eps, pcb_thick]); }; // LED and button holes translate([0, batt_diam/2-pcb_width/2, -infty/2]) { cylinder(r=led_diam/2, h=infty, $fn=6); translate([sw_xoff, 0, 0]) cylinder(r=sw_diam/2, h=infty, $fn=6); translate([-sw_xoff, 0, 0]) cylinder(r=sw_diam/2, h=infty, $fn=6); }; // wire hole from PCB to battery contacts rotate([-48, 0, 0]) translate([-batt_len/2-wall-cable_sep, 0, -wire_thick/2-wall/2]) cube([batt_len + 2*wall + 2* cable_sep, batt_diam/2 + wire_thick + wall, wire_thick]); // mounting holes for(x=[-1,1]) scale([x, 1, 1]) translate([batt_len/2-mounthole_w/2, batt_diam/2+wall+mounthole_h/2, -infty/2]) scale([1, mounthole_h/mounthole_w, 1]) cylinder(r = mounthole_w/2, h = infty); // holes in front of battery contacts for(x=[-1,1]) scale([x, 1, 1]) translate([batt_len/2-eps, wall/2-batt_contact_w/2, wall/2-batt_contact_h/2]) cube([wall+2*eps, batt_contact_w-wall, infty]); // holes for battery contacts for(x=[-1,1]) scale([x, 1, 1]) translate([batt_len/2+wall-eps, -batt_contact_w/2, -batt_contact_h/2]) cube([cable_sep+2*eps, batt_contact_w, infty]); // internal plus sign - vertical line translate([-batt_len/2 + 0.5*wall+plus_width/2, -plus_width/2, -batt_diam/2-wall]) cube([wall, plus_width, infty]); // internal plus and minus signs - horizontal line for(x=[-1,1]) scale([x, 1, 1]) translate([batt_len/2 - wall - plus_width, -wall/2, -batt_diam/2-wall]) cube([plus_width, wall, infty]); // button + label scale([-1, 1, 1]) 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]) cube([wall, plus_width, wall/2]); // button +/- label - horizontal line for (x=[-1, 1]) scale([x, 1, 1]) 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]) cube([plus_width, wall, wall/2]); }; }; module lid_body() { // outer part hull() { // smaller outermost part translate([-batt_len/2 - wall - cable_sep, -batt_diam/2, -batt_diam/2 - wall]) cube([batt_len + 2*wall + 2*cable_sep, batt_diam, eps]); // this part goes above the main body translate([-batt_len/2 - 2*wall - cable_sep, -batt_diam/2-wall, -body_top_h - lid_sep]) cube([batt_len + 4*wall + 2*cable_sep, batt_diam+2*wall, eps]); }; // the part which goes inside the main body translate([-batt_len/2 - wall - cable_sep + lid_sep, -batt_diam/2+lid_sep, -batt_diam/2 -wall]) 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]); // clips for (x = [-1, 1]) scale([1, x, 1]) translate([batt_len/6, batt_diam/2-lid_sep, - batt_end_h - clip_cyl_r - lid_sep]) rotate([0, -90, 0]) cylinder(r = clip_cyl_r, h = batt_len/3, $fn=4); // translate([batt_len/2 + wall + cable_sep - lid_sep, batt_diam/2 - lid_sep, -batt_end_h-lid_sep-clip_cyl_r]) } module lid() { difference() { lid_body(); translate([-batt_len/2-lid_sep, 0, 0]) rotate([0, 90, 0]) cylinder(r=batt_diam/2 + lid_sep, h=batt_len+2*lid_sep); // holes for battery contacts for(x=[-1,1]) scale([x, 1, 1]) translate([batt_len/2+wall-eps, -batt_contact_w/2, -batt_contact_h_lid/2]) cube([cable_sep+2*eps, batt_contact_w, infty]); }; }; if (lowres) { translate([0, 15, 0]) case(); translate([0, -15, 0]) rotate([180, 0, 0]) lid(); } else { translate([0, 15, batt_diam/2+pcb_thick+pcb_comp_h+pcb_comp_h2+wall]) case($fn=128); translate([0, -15, batt_diam/2+wall]) lid($fn=128); }