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 + 0.6; batt_len = 65 + 1.5; cable_sep = 1; // 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_groove = 1; body_top_h = 0.35 * batt_diam; // cube-shaped part of the body outwire_thick = 2.2; wire_thick = 2.2; wire_sep = 3.5; cable_out_diam = 5.2; batt_end_h = wire_sep/2 + wire_thick/2 + 1.5;; lid_sep = 0.5; // the lid is made this much smaller to separate from the body sw_diam = 2.5 + 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; rear_clip_hole_dist = 10; // distance between the holes in the rear clip rear_clip_aspect = 0.35; // w/h aspect ratio of the ellipse of the rear clip 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/2-2*pcb_comp_h-pcb_thick-wall]) cube([front_flat_len, pcb_width+wall, eps]); }; for (x = [-1, 1]) scale([x, 1, 1]) hull() { for (x0 = [0-wall, 10+wall]) translate([batt_len/2-wall-wire_thick-x0, batt_diam/2, 0]) rotate([-90, 0, 0]) scale([rear_clip_aspect, 1, 1]) cylinder(r=batt_diam/2 + 2*wall + wire_thick, h=wall); }; }; 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 translate([-pcb_len/2-pcb_xoff-wall-2*outwire_thick, batt_diam/2-pcb_width, -batt_diam/2-pcb_comp_h]) cube([pcb_len, pcb_width, batt_diam/2 + pcb_comp_h + eps]); // hole under the PCB translate([-pcb_len/2+pcb_groove-pcb_xoff, batt_diam/2-pcb_width + pcb_groove, -batt_diam/2-pcb_thick - 2*pcb_comp_h]) cube([pcb_len-2*pcb_groove, pcb_width-2*pcb_groove, batt_diam/2 + pcb_thick + pcb_comp_h + 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 - 2*pcb_comp_h]) 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_h]) cube([prg_len/2+eps, prg_width+2*eps, pcb_thick]); }; // LED hole 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); }; // cable outlet translate([-pcb_xoff-pcb_len/2-outwire_thick-wall, -6, 0]) rotate([40, 0, 0]) scale([2, 1, -1]) cylinder(r=outwire_thick/2, h = infty, $fn=12); // 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, 0, 0]) hull() { translate([0, -batt_diam/2, 0]) cube([wall + cable_sep + eps, batt_diam, infty]); rotate([0, 90, 0]) cylinder(r = batt_diam/2, h = wall+cable_sep+eps); translate([0, batt_diam/2 - pcb_width, -batt_diam/2-pcb_comp_h-pcb_thick]) cube([wall + cable_sep + eps, pcb_width, eps]); translate([cable_sep, batt_diam/2 - pcb_width + 1.5*wall, -batt_diam/2-pcb_comp_h-pcb_thick-wall]) cube([wall + eps, pcb_width-2*wall, eps]); }; // cable lead to battery contacts for (x=[1, -1]) scale([x, 1, 1]) rotate([-140, 0, 0]) translate([batt_len/2+wire_thick/2, 0, batt_diam/2-2*wall]) cylinder(r=wire_thick/2, h = 5); // mounting holes for(x=[-1,1]) scale([x, 1, 1]) translate([batt_len/2-wall-wire_thick, batt_diam/2+2*wall, -batt_diam/2-pcb_thick-2*pcb_comp_h-wall]) vert_torus(); for (x = [-1, 1]) scale([x, 1, 1]) for (x0 = [0, 10]) translate([batt_len/2-wall-wire_thick-x0, 0, batt_diam/2+wire_thick/2+wall]) rotate([-90, 0, 0]) scale([2,1,1]) cylinder (r=wire_thick/2, h=infty, $fn=16); }; // clip barrier for (x = [-1, 1]) scale([x, 1, 1]) translate([batt_len/2+wall-eps, batt_diam/2-pcb_width+wall+lid_sep, -batt_diam/2-pcb_thick-pcb_comp_h + wall + lid_sep]) cube([cable_sep+eps, pcb_width-2*wall-2*lid_sep, wall]); }; module lid_body() { translate([-batt_len/2 - wall - lid_sep, -batt_diam/2+lid_sep, -batt_diam/2 -wall]) cube([batt_len + 2*wall + 2*lid_sep, batt_diam-2*lid_sep, batt_diam/2 - batt_end_h + wall - lid_sep]); translate([-batt_len/2 - 2*wall - cable_sep, -batt_diam/2 - wall, -batt_diam/2-wall]) cube([batt_len + 4*wall + 2*cable_sep, batt_diam + 2*wall, wall + batt_diam/2 - body_top_h - lid_sep]); // clip behind the battery contacts for(x=[1, -1]) scale([x, 1, 1]) translate([batt_len/2+wall+lid_sep, 0, 0]) hull() { translate([0, -batt_diam/2+lid_sep, -batt_diam/2]) cube([wall+cable_sep-lid_sep, batt_diam-2*lid_sep, eps]); rotate([0, 90, 0]) cylinder(r = batt_diam/2-lid_sep, h = wall+cable_sep-lid_sep); translate([0, batt_diam/2 - pcb_width+lid_sep, batt_diam/2+pcb_comp_h+pcb_thick-lid_sep]) cube([wall+cable_sep-lid_sep, pcb_width-2*lid_sep, eps]); translate([cable_sep+wall/2, batt_diam/2 - pcb_width + 1.5*wall +lid_sep, batt_diam/2+pcb_comp_h+pcb_thick+wall/2-lid_sep]) cube([wall/2-lid_sep, pcb_width-2*wall-2*lid_sep, 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); 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]); }; // holes for the mounting clips on the body for (x = [-1, 1]) scale([x, 1, 1]) hull() { for (x0 = [0-wall, 10+wall]) translate([batt_len/2-wall-wire_thick-x0, batt_diam/2-lid_sep+eps, 0]) rotate([-90, 0, 0]) scale([rear_clip_aspect, 1, 1]) cylinder(r=batt_diam/2 + 2*wall + wire_thick+lid_sep/rear_clip_aspect, h=wall+lid_sep+eps); }; }; }; module vert_torus() { rotate([0, 90, 0]) scale([1, 1, 2]) rotate_extrude() translate([5, 0, 0]) circle(r=wire_thick/2, $fn=16); }; if (lowres) { translate([0, 15, 0]) case(); translate([0, -15, 0]) rotate([180, 0, 0]) lid(); } else { translate([0, 15, batt_diam/2+pcb_thick+2*pcb_comp_h+wall]) case($fn=128); translate([0, -15, batt_diam/2+wall]) lid($fn=128); }