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 = 0.35 * batt_diam; // cube-shaped part of the body wire_thick = 2.2; wire_sep = 3.5; batt_end_h = wire_sep/2 + wire_thick/2 + 1.5;; 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 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, -batt_diam/2-pcb_comp_h-pcb_comp_h2-pcb_thick-wall]) cube([front_flat_len, pcb_width+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_diam]); // 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); }; // space under the wire holes for battery contacts translate([-batt_len/2-2*wall-cable_sep-eps, 0, 0]) difference() { rotate([0, 90, 0]) cylinder(r = batt_diam/2-wall, h = batt_len + 4*wall + 2*cable_sep + 2*eps); translate([-infty/2, -infty/2, -batt_end_h]) cube(infty); }; // space above the wire holes for battery contacts translate([-batt_len/2-2*wall-cable_sep-eps, -batt_diam/2, batt_end_h]) cube([batt_len + 4*wall + 2*cable_sep + 2*eps, batt_diam, batt_end_h]); // wire holes for battery contacts for (x = [-1, 1]) for (y = [-1, 1]) translate([-batt_len/2-wall-eps, x*wire_sep/2, y*wire_sep/2]) rotate([0, 90, 0]) cylinder(r = wire_thick/2, h = batt_len + 2*wall + 2*eps, $fn=6); // wire hole from PCB to battery contacts // translate([-batt_len/2-wall-eps, 0, -batt_diam/2-pcb_comp_h + wire_thick/2]) rotate([40, 0, 0]) translate([-batt_len/2-wall-eps, 0, -batt_diam/2 - wall/2 - wire_thick/2]) rotate([0, 90, 0]) cylinder(r = wire_thick/2, h = batt_len + 2*wall + 2*eps, $fn=6); // hole behind the battery contacts for(x=[1, -1]) scale([x, 1, 1]) translate([batt_len/2+wall+cable_sep, 0, 0]) hull() { translate([0, -batt_diam/2, 0]) cube([wall + eps, batt_diam, infty]); rotate([0, 90, 0]) cylinder(r = batt_diam/2, h = wall+eps); translate([0, batt_diam/2 - pcb_width, -batt_diam/2-pcb_comp_h-pcb_thick]) cube([wall + eps, pcb_width, eps]); translate([0, batt_diam/2 - pcb_width + 0.5*wall, -batt_diam/2-pcb_comp_h-pcb_comp_h2-pcb_thick]) cube([wall + eps, pcb_width-0.5*wall, eps]); }; // inner hole behind the battery contacts for(x=[1, -1]) scale([x, 1, 1]) translate([batt_len/2+wall, 0, 0]) hull() { translate([0, -batt_diam/2+wall, 0]) cube([cable_sep + eps, batt_diam-2*wall, infty]); rotate([0, 90, 0]) cylinder(r = batt_diam/2-wall, h = cable_sep+eps); }; // cable lead to battery contacts for (x=[1, -1]) scale([x, 1, 1]) rotate([-140, 0, 0]) translate([batt_len/2-eps, -wire_thick/2, batt_diam/2-2.7]) cube([wall+cable_sep+2*eps, wire_thick, 5.4]); // 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); // grabbing gap for(x=[-1,1]) scale([x, 1, 1]) translate([batt_len/2+cable_sep+wall+10, batt_diam/2-pcb_width/2, -batt_diam/2-pcb_comp_h-pcb_comp_h2-pcb_thick-wall-eps]) cylinder(r1 = 10, r2 = 10 - wall, h = wall + 2*eps); // 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]); // rounded top for (x=[-1, 1]) scale([x, 1, 1]) translate([batt_len/2 + wall + cable_sep, -infty/2, body_top_h - 2*wall]) rotate([-90, 0, 0]) scale([1, -2, 1]) difference() { cube([wall+eps, wall+eps, infty]); translate([0, 0, -eps]) cylinder(r=wall, h=infty+2*eps); } }; // clip barrier for (x = [-1, 1]) scale([x, 1, 1]) hull () { translate([batt_len/2+wall+cable_sep-eps, batt_diam/2-pcb_width+wall/2+lid_sep, -batt_diam/2-pcb_thick-pcb_comp_h + wall + lid_sep]) cube([wall+eps, pcb_width-2*wall-2*lid_sep, wall]); translate([batt_len/2+wall+cable_sep-eps, batt_diam/2-pcb_width+3*wall/2+lid_sep, -batt_diam/2-pcb_thick-pcb_comp_h + 3*wall + lid_sep]) cube([eps, pcb_width-4*wall-2*lid_sep, eps]); }; }; module lid_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]); hull () { translate([-batt_len/2 - 2*wall - cable_sep, -batt_diam/2, -batt_diam/2-wall]) cube([batt_len + 4*wall + 2*cable_sep, batt_diam, eps]); translate([-batt_len/2 - 3*wall - cable_sep, -batt_diam/2 - wall, -body_top_h-wall/2-lid_sep]) cube([batt_len + 6*wall + 2*cable_sep, batt_diam + 2*wall, wall/2]); }; // clip behind the battery contacts for(x=[1, -1]) scale([x, 1, 1]) translate([batt_len/2+wall+cable_sep+lid_sep, 0, 0]) hull() { translate([0, -batt_diam/2+lid_sep, -batt_diam/2]) cube([wall-lid_sep, batt_diam-2*lid_sep, eps]); rotate([0, 90, 0]) cylinder(r = batt_diam/2-lid_sep, h = wall-lid_sep); translate([-clip_pretension, batt_diam/2 - pcb_width + 0.5*wall + lid_sep, batt_diam/2+pcb_comp_h+pcb_comp_h2+pcb_thick-lid_sep]) cube([wall+clip_pretension, pcb_width-0.5*wall-1.5*lid_sep, eps]); }; // outer part of the clip behind the battery contacts for (x=[1, -1]) scale([x, 1, 1]) translate([batt_len/2+2*wall+cable_sep+lid_sep, 0, 0]) hull() { translate([0, -batt_diam/2 - wall, -body_top_h-wall/2-lid_sep]) cube([wall-lid_sep, batt_diam + 2*wall, wall/2]); difference() { scale([0.3, 1, 1]) sphere(batt_diam/2+wall); translate([-infty/2, -infty/2, -infty-body_top_h-lid_sep+2*wall]) cube(infty); translate([-infty-clip_pretension, -infty/2, -infty/2]) cube(infty); }; translate([-clip_pretension, batt_diam/2 - pcb_width, batt_diam/2+pcb_comp_h+pcb_comp_h2+pcb_thick+wall]) cube([wall-lid_sep, pcb_width+wall, eps]); }; }; module lid() { difference() { lid_body(); translate([-batt_len/2+eps, 0, 0]) rotate([0, 90, 0]) cylinder(r=batt_diam/2, h=batt_len-2*eps); // clip barrier for (x = [-1, 1]) scale([x, 1, 1]) hull () { translate([batt_len/2+wall+cable_sep-clip_pretension, batt_diam/2-pcb_width+wall/2, batt_diam/2+pcb_thick+pcb_comp_h-2*wall]) cube([wall+clip_pretension+eps, pcb_width-2*wall, wall]); translate([batt_len/2+wall+cable_sep-eps, batt_diam/2-pcb_width+wall/2, batt_diam/2+pcb_thick+pcb_comp_h-4*wall + lid_sep]) cube([eps, pcb_width-2*wall, eps]); }; /* hull() { difference() { translate([-batt_len/2-cable_sep-wall, 0, 0]) rotate([0, 90, 0]) cylinder(r=batt_diam/2-wall-lid_sep, h=batt_len+2*wall+2*cable_sep); translate([-infty/2, -batt_diam/2, -infty-wire_sep/2-wire_thick/2]) cube([infty, batt_diam, infty]); }; 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]) cube([batt_len + 2*wall + 2* cable_sep, pcb_width-1.5*wall-1.5*lid_sep, eps]); }; */ }; }; 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); }