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_comp_h2 = 4.5;      // height of the components on board - component side
  23 pcb_groove = 1;
  24
  25 body_top_h = 0.38 * batt_diam; // cube-shaped part of the body
  26
  27 wire_thick = 2.5;
  28 wire_sep = 3.5;
  29
  30 lid_sep = 0.2; // the lid is made this much smaller to separate from the body
  31
  32 // sw_diam = 2.5 + 0.5;
  33 sw_diam = 3.5 + 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 batt_contact_w = 12;
  56 batt_contact_h = 14;
  57 batt_contact_h_lid = batt_contact_h-2;
  58 clip_cyl_r = 0.7;
  59 batt_end_h = body_top_h - 4*clip_cyl_r;;
  60
  61
  62 module case_body() {
  63         hull() {
  64                 translate([-batt_len/2-2*wall-cable_sep, -batt_diam/2-wall, 0])
  65                         cube([batt_len + 4*wall + 2*cable_sep,
  66                                 batt_diam+2*wall, body_top_h]);
  67                 difference() {
  68                         translate([-batt_len/2-2*wall-cable_sep, 0, 0])
  69                                 rotate([0, 90, 0])
  70                                 cylinder(r=batt_diam/2+wall,
  71                                         h = batt_len + 4*wall + 2*cable_sep);
  72                         translate([-infty/2, -infty/2, eps]) cube(infty);
  73                 };
  74                 translate([-front_flat_len/2,
  75                         batt_diam/2 - pcb_width-0.5*wall,
  76                         -batt_diam/2-pcb_comp_h-pcb_comp_h2-pcb_thick-wall])
  77                         cube([front_flat_len, pcb_width+1.5*wall, eps]);
  78         };
  79         // mounting cylinders
  80         for (x = [-1, 1]) translate([x*(batt_len/2-mounthole_w/2),
  81                 batt_diam/2+wall, 0]) {
  82                         translate([0, 0, -batt_diam/2-wall-pcb_comp_h-pcb_comp_h2-pcb_thick])
  83                                 mount_cyl(); // front
  84                         translate([0, 0, body_top_h]) // rear
  85                                 scale([1, 1, -1])
  86                                 mount_cyl();
  87         };
  88 };
  89
  90 module mount_cyl() {
  91         assign(h = mounthole_h+wall)
  92         hull () {
  93                 translate([0, -mountcyl_w/2+mounthole_h + wall])
  94                         cylinder(r = mountcyl_w/2, h = mountcyl_h);
  95                 assign(l = 2*sqrt(h*(mountcyl_w-h)))
  96                 translate([-l/2, 0, mountcyl_h + mountcone_h])
  97                         cube([l, eps, eps]);
  98         };
  99 };
 100
 101 module case() {
 102         difference() {
 103                 case_body();
 104                 // upper cube-shaped part
 105                 // rotate([20, 0, 0])
 106                 translate([-batt_len/2, -batt_diam/2, 0])
 107                         cube([batt_len, batt_diam, batt_end_h+eps]);
 108                 // upper longer cube-shaped part
 109                 difference() {
 110                         translate([-batt_len/2-cable_sep-wall, -batt_diam/2, batt_end_h])
 111                                 cube([batt_len+2*cable_sep+2*wall, batt_diam, batt_diam]);
 112                         // clips
 113                         for (x = [-1,1]) scale([1, x, 1])
 114                                 translate([batt_len/6, batt_diam/2, batt_end_h + 3*clip_cyl_r])
 115                                 rotate([0, -90, 0])
 116                                 cylinder(r = clip_cyl_r, h = batt_len/3, $fn=4);
 117                 }
 118                 // grabbing holes
 119                 for (x=[-1,1]) scale([x,1,1])
 120                 translate([batt_len/2 + 2*wall + cable_sep+10-wall, 0, 0])
 121                         cylinder(r1 = 7, r2 = 10, h = body_top_h + eps);
 122                 // battery cylinder for the lower part
 123                 translate([-batt_len/2, 0, 0])
 124                         rotate([0, 90, 0])
 125                         cylinder(r=batt_diam/2, h = batt_len);
 126
 127                 // hole for PCB
 128                 translate([-pcb_len/2-pcb_xoff,
 129                         batt_diam/2-pcb_width,
 130                         -batt_diam/2-pcb_thick - pcb_comp_h])
 131                         cube([pcb_len, pcb_width,
 132                                 batt_diam/2 + pcb_thick + pcb_comp_h + eps]);
 133                 // hole above the PCB for the outgoing cable
 134                 translate([-pcb_len/2-pcb_xoff-2*wall-outcable_w,
 135                         batt_diam/2-pcb_width,
 136                         -batt_diam/2-pcb_comp_h])
 137                         cube([pcb_len, pcb_width,
 138                                 batt_diam/2 + pcb_comp_h + eps]);
 139                 // cable outlet
 140                 translate([-pcb_xoff-pcb_len/2-wall-outcable_w,
 141                         -pcb_width+batt_diam/2,
 142                         -batt_diam/2-outcable_h])
 143                         cube([outcable_w, infty, outcable_h]);
 144                 // hole under the PCB (groove)
 145                 translate([-pcb_len/2+pcb_groove-pcb_xoff,
 146                         batt_diam/2-pcb_width + pcb_groove,
 147                         -batt_diam/2-pcb_thick - pcb_comp_h - pcb_comp_h2])
 148                         cube([pcb_len-2*pcb_groove, pcb_width-2*pcb_groove,
 149                                 batt_diam/2 + pcb_thick + pcb_comp_h2 + eps]);
 150                 // hole under the PCB (pcb-width)
 151                 translate([-pcb_len/2+2*pcb_groove-pcb_xoff,
 152                         batt_diam/2-pcb_width,
 153                         -batt_diam/2-pcb_thick - pcb_comp_h - pcb_comp_h2])
 154                         cube([pcb_len-4*pcb_groove, pcb_width,
 155                                 batt_diam/2 + pcb_thick + pcb_comp_h2 + eps]);
 156                 // hole for prog connector
 157                 translate([pcb_len/2-pcb_xoff-pcb_groove-eps,
 158                         batt_diam/2-pcb_width/2-prg_width/2,
 159                         -batt_diam/2-pcb_thick - pcb_comp_h - pcb_comp_h2])
 160                         difference() {
 161                                 cube([prg_len+pcb_groove+eps, prg_width,
 162                                         batt_diam/2 + pcb_thick + pcb_comp_h + eps]);
 163                                 translate([prg_len/2+pcb_groove, -eps, pcb_comp_h2])
 164                                         cube([prg_len/2+eps, prg_width+2*eps, pcb_thick]);
 165                         };
 166                 // LED and button holes
 167                 translate([0, batt_diam/2-pcb_width/2, -infty/2]) {
 168                         cylinder(r=led_diam/2, h=infty, $fn=6);
 169                         translate([sw_xoff, 0, 0])
 170                                 cylinder(r=sw_diam/2, h=infty, $fn=6);
 171                         translate([-sw_xoff, 0, 0])
 172                                 cylinder(r=sw_diam/2, h=infty, $fn=6);
 173                 };
 174                 // wire hole from PCB to battery contacts
 175                 rotate([-48, 0, 0])
 176                 translate([-batt_len/2-wall-cable_sep, 0, -wire_thick/2-wall/2])
 177                         cube([batt_len + 2*wall + 2* cable_sep, batt_diam/2 + wire_thick + wall, wire_thick]);
 178                 // mounting holes
 179                 for(x=[-1,1]) scale([x, 1, 1])
 180                 translate([batt_len/2-mounthole_w/2, batt_diam/2+wall+mounthole_h/2, -infty/2])
 181                         scale([1, mounthole_h/mounthole_w, 1])
 182                         cylinder(r = mounthole_w/2, h = infty);
 183                 // holes in front of battery contacts
 184                 for(x=[-1,1]) scale([x, 1, 1])
 185                 translate([batt_len/2-eps, wall/2-batt_contact_w/2,
 186                         wall/2-batt_contact_h/2])
 187                         cube([wall+2*eps, batt_contact_w-wall, infty]);
 188                 // holes for battery contacts
 189                 for(x=[-1,1]) scale([x, 1, 1])
 190                 translate([batt_len/2+wall-eps, -batt_contact_w/2,
 191                         -batt_contact_h/2])
 192                         cube([cable_sep+2*eps, batt_contact_w, infty]);
 193                 // internal plus sign - vertical line
 194                 translate([-batt_len/2 + 0.5*wall+plus_width/2, -plus_width/2, -batt_diam/2-wall])
 195                         cube([wall, plus_width, infty]);
 196                 // internal plus and minus signs - horizontal line
 197                 for(x=[-1,1]) scale([x, 1, 1])
 198                 translate([batt_len/2 - wall - plus_width, -wall/2, -batt_diam/2-wall])
 199                         cube([plus_width, wall, infty]);
 200                 // button + label
 201                 scale([-1, 1, 1])
 202                 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])
 203                         cube([wall, plus_width, wall/2]);
 204                 // button +/- label - horizontal line
 205                 for (x=[-1, 1]) scale([x, 1, 1])
 206                 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])
 207                         cube([plus_width, wall, wall/2]);
 208         };
 209 };
 210
 211 module lid_body() {
 212         // outer part
 213         hull() {
 214                 // smaller outermost part
 215                 translate([-batt_len/2 - wall - cable_sep, -batt_diam/2, -batt_diam/2 - wall])
 216                         cube([batt_len + 2*wall + 2*cable_sep, batt_diam, eps]);
 217                 // this part goes above the main body
 218                 translate([-batt_len/2 - 2*wall - cable_sep, -batt_diam/2-wall, -body_top_h - lid_sep])
 219                         cube([batt_len + 4*wall + 2*cable_sep, batt_diam+2*wall, eps]);
 220         };
 221         // the part which goes inside the main body
 222         translate([-batt_len/2 - wall - cable_sep + lid_sep, -batt_diam/2+lid_sep, -batt_diam/2 -wall])
 223                 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]);
 224         // clips
 225         for (x = [-1, 1]) scale([1, x, 1])
 226                 translate([batt_len/6, batt_diam/2-lid_sep, - batt_end_h - clip_cyl_r - lid_sep])
 227                 rotate([0, -90, 0])
 228                 cylinder(r = clip_cyl_r, h = batt_len/3, $fn=4);
 229         // translate([batt_len/2 + wall + cable_sep - lid_sep, batt_diam/2 - lid_sep, -batt_end_h-lid_sep-clip_cyl_r])
 230 }
 231
 232 module lid() {
 233         difference() {
 234                 lid_body();
 235                 translate([-batt_len/2-lid_sep, 0, 0]) rotate([0, 90, 0])
 236                         cylinder(r=batt_diam/2 + lid_sep, h=batt_len+2*lid_sep);
 237                 // holes for battery contacts
 238                 for(x=[-1,1]) scale([x, 1, 1])
 239                 translate([batt_len/2+wall-eps, -batt_contact_w/2,
 240                         -batt_contact_h_lid/2])
 241                         cube([cable_sep+2*eps, batt_contact_w, infty]);
 242         };
 243 };
 244
 245 if (lowres) {
 246         translate([0, 15, 0]) case();
 247         translate([0, -15, 0]) rotate([180, 0, 0]) lid();
 248 } else {
 249         translate([0, 15, batt_diam/2+pcb_thick+pcb_comp_h+pcb_comp_h2+wall])
 250                 case($fn=128);
 251         translate([0, -15, batt_diam/2+wall])
 252                 lid($fn=128);
 253 }
 254