update

cases/math.scad

@@ -0,0 +1,12 @@
+
+/* Example usage:
+for (i=mirror4XY(midpoint=[0,0,0], offsetX=90, offsetY=90)) {
+    translate(v=i)
+        something();
+}
+*/
+function mirror4XY(midpoint, offsetX, offsetY)  =
+    [[midpoint[0]+offsetX, midpoint[1]+offsetY, midpoint[2]],
+        [midpoint[0]-offsetX, midpoint[1]+offsetY, midpoint[2]],
+        [midpoint[0]-offsetX, midpoint[1]-offsetY, midpoint[2]],
+        [midpoint[0]+offsetX, midpoint[1]-offsetY, midpoint[2]]];

cases/misc/magnet.scad

@@ -0,0 +1,6 @@
+
+
+// Dimensions for small cylindrical neodymium magnets that I bought off Amazon
+magnetD = 6;
+magnetR = magnetD/2;
+magnetH = 1.7;

cases/misc/voronoi.scad

@@ -0,0 +1,95 @@
+
+// (c)2013 Felipe Sanches <juca@members.fsf.org>
+// licensed under the terms of the GNU GPL version 3 (or later)
+
+function normalize(v) = v / (sqrt(v[0] * v[0] + v[1] * v[1]));
+
+//
+// The voronoi() function generates a 2D surface, which can be provided to
+// a) linear_extrude() to produce a 3D object
+// b) intersection() to restrict it to a a specified shape -- see voronoi_polygon.scad
+//
+// Parameters:
+//   points (required) ... nuclei coordinates (array of [x, y] pairs)
+//   L                 ... the radius of the "world" (the pattern is built within this circle)
+//   thickness         ... the thickness of the lines between cells
+//   round             ... the radius applied to corners (fillet in CAD terms)
+//   nuclei (bool)     ... show nuclei sites
+//
+// These parameters need to be kept more or less in proportion to each other, and to the distance
+// apart of points in the point_set. If one or the other parameter is increased or decreased too
+// much, you'll get no output.
+//
+module voronoi(points, L = 200, thickness = 1, round = 6, nuclei = true) {
+	for (p = points) {
+		difference() {
+			minkowski() {
+				intersection_for(p1 = points){
+					if (p != p1) {
+						angle = 90 + atan2(p[1] - p1[1], p[0] - p1[0]);
+
+						translate((p + p1) / 2 - normalize(p1 - p) * (thickness + round))
+						rotate([0, 0, angle])
+						translate([-L, -L])
+						square([2 * L, L]);
+					}
+				}
+				circle(r = round, $fn = 20);
+			}
+			if (nuclei)
+				translate(p) circle(r = 1, $fn = 20);
+		}
+	}
+}
+
+//
+// The random_voronoi() function is the helper wrapper over the voronoi() core.
+// It generates random nuclei site coordinates into the square area,
+// passing other arguments to voronoi() unchanged.
+//
+// Parameters:
+//   n                 ... number of nuclei sites to be generated
+//   nuclei (bool)     ... show nuclei sites
+//   L                 ... the radius of the "world" (the pattern is built within this circle)
+//   thickness         ... the thickness of the lines between cells
+//   round             ... the radius applied to corners (fillet in CAD terms)
+//   min               ... minimum x and y coordinate for nuclei generation
+//   max               ... maximum x and y coordinate for nuclei generation
+//   seed              ... seed for the random generator (random if undefined)
+//   center (bool)     ... move resulting pattern to [0, 0] if true
+//
+module random_voronoi(n = 20, nuclei = true, L = 200, thickness = 1, round = 6, min = 0, max = 100, seed = undef, center = false) {
+	seed = seed == undef ? rands(0, 100, 1)[0] : seed;
+	echo("Seed", seed);
+
+	// Generate points.
+	x = rands(min, max, n, seed);
+	y = rands(min, max, n, seed + 1);
+	points = [ for (i = [0 : n - 1]) [x[i], y[i]] ];
+        
+	// Center Voronoi.
+	offset_x = center ? -(max(x) - min(x)) / 2 : 0;
+	offset_y = center ? -(max(y) - min(y)) / 2 : 0;
+	translate([offset_x, offset_y])
+    
+	voronoi(points, L = L, thickness = thickness, round = round, nuclei = nuclei);
+}
+
+// example with an explicit list of points:
+point_set = [
+	[0, 0], [30, 0], [20, 10], [50, 20], [15, 30], [85, 30], [35, 30], [12, 60],
+	[45, 50], [80, 80], [20, -40], [-20, 20], [-15, 10], [-15, 50]
+];
+//voronoi(points = point_set, round = 4, nuclei = true);
+
+module voronoi3u_N(h) {
+  intersection() {
+    translate(v=[10,5,0])
+      cube(size=[160, 10, h]);
+    translate(v=[20,-52,0])
+      scale(v=[0.40,0.44,10])
+      linear_extrude(height=10)
+      random_voronoi(n = 128, round = 10, min = 0, max = 300, seed = 40, thickness=3.5, nuclei=false);
+  }
+}
+

cases/open-frame.scad

@@ -1,14 +1,8 @@
 $fn=64;
+include <./math.scad>
 
 eps=0.1;
 
-
-function mirror4XY(midpoint, offsetX, offsetY)  =
-  [[midpoint[0]+offsetX, midpoint[1]+offsetY, midpoint[2]],
-   [midpoint[0]-offsetX, midpoint[1]+offsetY, midpoint[2]],
-   [midpoint[0]-offsetX, midpoint[1]-offsetY, midpoint[2]],
-   [midpoint[0]+offsetX, midpoint[1]-offsetY, midpoint[2]]];
-
 module leg() {
     mainLength = 80;
     upperDim = 20;

cases/profiles/rpi/frontPlate.scad

@@ -92,9 +92,27 @@ module frontPlate() {
 
 difference() {
 difference() {
-    union() {
+
-        rotate(a=[-90,0,0])
+    difference() {
-            frontPlate();
+        union() {
+            rotate(a = [- 90, 0, 0])
+                frontPlate();
+        }
+
+        union() {
+            translate(v=[1,0,0])
+                rotate(a=[0,-15, 0])
+                    translate(v=[0,-50,0])
+                        cube(size=[100, 100, 30]);
+
+            translate(v=[180-1,0,0])
+                mirror(v=[1,0,0]) {
+                    rotate(a = [0, - 15, 0])
+                        translate(v = [0, - 50, 0])
+                            cube(size = [100, 100, 30]);
+                }
+        }
+
     }
     // lug holes
     union() {
@@ -105,7 +123,7 @@ difference() {
     }
 }
     for (i=[0:5]) {
-        translate(v=[5,i*4 - 0.5,-10])
+        translate(v=[5,i*4 - 0.75,-10])
-        cube(size=[170, 2, 20]);
+        cube(size=[170, 1.5, 20]);
     }
 }

cases/profiles/rpi/rpi2b.scad

@@ -134,11 +134,11 @@ module cutoutProfile_N() {
     // front I/O
     mirror(v=[0,1,0])
       translate(v=[1, -eps*100, pcbThickness-4])
-      cube(size=[58.0 + 0.1, inf50,  18.0 + 0.1]);
+      cube(size=[58.0 + 0.1, inf50,  19.0 + 0.1]);
 
     // side I/O
     translate(v=[-48-3, (pcbDimensions[1]-54)-10, pcbThickness-4])
-    cube(size=[inf50, 64, 18]);
+    cube(size=[inf50, 64, 19]);
   }
 
 }

cases/profiles/rpi/top.scad

@@ -4,7 +4,7 @@ difference() {
   union() {
     cube(size=[67,95.7,1]);
     translate(v=[2,2,1])
-    cube(size=[63,91.7,3]);
+    cube(size=[63.2,92,3]);
   }
 
   union() {

cases/rack/body/base1.scad

@@ -1,5 +1,5 @@
-include <../common.scad>
+include <../../common.scad>
-include <./screws.scad>
+include <../screws.scad>
 
 $fn=64;
 

cases/rack/body/m4Leg.scad

@@ -1,5 +1,5 @@
-include <../common.scad>
+include <../../common.scad>
-include <./screws.scad>
+include <../screws.scad>
 
 
 //slack = 0.5;

cases/rack/body/side/side.scad

@@ -1,19 +1,88 @@
-sideHeight = 210;
+include <../../../misc/magnet.scad>
-sideLength = 200;
+include <../../../math.scad>
+$fn=64;
+
+_height = 210;
+_depth = 200;
+
+_thickness = 5;
 
 holeOffset = 10;
 
+module _base() {
+    difference() {
+        cube(size = [_height, _depth, _thickness], center=true);
+        union() {
+            translate(v = [0, 0, 20])
+                minkowski() {
+                    sphere(r = 20);
+                    cube(size = [_height - 34, _depth - 34, 1], center = true);
 
-// TODO make helper function for this
+                }
-screwDiffs = [
+            // handles
-        [sideLength-holeOffset, sideHeight-holeOffset,0],
+            handleLength = 80;
-        [holeOffset, holeOffset,0],
+            translate(v=[0, _depth/2, _thickness+5.5])
-        [sideLength-holeOffset, holeOffset],
+                minkowski() {
-        [holeOffset, sideHeight-holeOffset],
+                    sphere(r=10);
+                    cube(size=[handleLength, 10, 1], center=true);
+                }
+            translate(v=[0, -_depth/2, _thickness+5.5])
+                minkowski() {
+                    sphere(r=10);
+                    cube(size=[handleLength, 10, 1], center=true);
+                }
+        }
+    }
+}
+
+module magnetMount(h) {
+    slack = 0.2;
+    difference() {
+        cylinder(h = h, r=magnetR*2);
+        translate(v=[0,0,h-magnetH])
+        cylinder(h = magnetH, r = magnetR+slack);
+    }
+}
+
+
+module side() {
+    magnetMountOffsetX = 95;
+    magnetMountOffsetY = 90;
+    difference() {
+        union() {
+            // align _base to positive z plan
+            translate(v = [0, 0, _thickness / 2])
+                _base();
+
+            // magnet mounts (no holes)
+            for (i=mirror4XY(midpoint=[0,0,0], offsetX=magnetMountOffsetX, offsetY=magnetMountOffsetY)) {
+                translate(v=i)
+                    cylinder(h=_thickness, r=2*magnetR);
+            }
+        }
+
+        // magnet mount holes
+        for (i=mirror4XY(midpoint=[0,0,_thickness-magnetH], offsetX=magnetMountOffsetX, offsetY=magnetMountOffsetY)) {
+            translate(v=i)
+                cylinder(h=magnetH, r=magnetR);
+        }
+    }
+}
+
+
+difference() {
+    side();
+
+    union() {
+        for (i=[0:7]) {
+            translate(v=[i*15 - 52.5,0,0])
+            minkowski() {
+                cube(size = [2, 100, 10], center = true);
+                sphere(r=2);
+            }
+        }
+
+    }
+}
 
-        [sideLength-2*holeOffset, sideHeight-holeOffset,0],
-        [2*holeOffset, holeOffset,0],
-        [sideLength-2*holeOffset, holeOffset],
-        [2*holeOffset, sideHeight-holeOffset]
-];
 

cases/rack/body/top1.scad

@@ -1,79 +1,97 @@
-include <../common.scad>
+include <../../common.scad>
-include <./screws.scad>
+include <../../math.scad>
+include <../screws.scad>
 
 $fn=64;
 
-module baseFrame() {
+_height = 8;
-  difference() {
+_width = 210;
-    cube(size=[200,200,4], center=true);
+_depth = 200;
-    cube(size=[180,180,4], center=true);
-  }
-
-  translate(v=[80,80,0])
-  cube(size=[20,20, 4],center=true);
-
-  translate(v=[-80,80,0])
-  cube(size=[20,20, 4],center=true);
-
-  translate(v=[80,-80,0])
-  cube(size=[20,20, 4],center=true);
-
-  translate(v=[-80,-80,0])
-  cube(size=[20,20, 4],center=true);
-}
-
-module lugBottom() {
-  difference() {
-    cube(size=[9.7,9.7,6], center=true);
-
-    translate(v=[2,2,0])
-    cube(size=[9.1,9.1,5+1], center=true);
-  }
-  
-}
 
 
-module base() {
+module _bodySilBase(width, depth, height, roundedPartHeight) {
+  hull() {
+    cube(size = [width, depth, height - roundedPartHeight]);
+    minkowski() {
+      translate(v = [roundedPartHeight, 0, height - roundedPartHeight])
+        cube(size = [width-2*roundedPartHeight, depth, eps]);
 
-  difference() {
+      rotate(a = [90, 0, 0])
-    union() {
+        cylinder(r = roundedPartHeight, h = eps);
-      translate(v=[0,0,4/2])
-        baseFrame();
-
-
-      translate(v=[-90,-90,-6/2])
-        lugBottom();
-
-      mirror(v=[1,0,0])
-        translate(v=[-90,-90,-6/2])
-        lugBottom();
-
-      mirror(v=[0,1,0])
-        translate(v=[-90,-90,-6/2])
-        lugBottom();
-
-      mirror(v=[1,1,0])
-        translate(v=[-90,-90,-6/2])
-        lugBottom();
-    }
-
-    union() {
-      translate(v=[80,80,0]) 
-      cylinder(h = 100, r = m3ptr, $fn=32, center=true);
-
-      translate(v=[-80,80,0]) 
-      cylinder(h = 100, r = m3ptr, $fn=32, center=true);
-
-      translate(v=[80,-80,0]) 
-      cylinder(h = 100, r = m3ptr, $fn=32, center=true);
-
-      translate(v=[-80,-80,0]) 
-      cylinder(h = 100, r = m3ptr, $fn=32, center=true);
-      
     }
   }
 }
 
-base();
+module _bodySil(width, depth, height, roundedPartHeight, wallThickness, topThickness) {
+  cornerSquareDim = 30;
+
+  difference() {
+    _bodySilBase(width, depth, height, roundedPartHeight);
+
+    union() {
+      translate(v = [wallThickness, cornerSquareDim, - topThickness])
+        _bodySilBase(width - 2 * wallThickness, depth - 2 * cornerSquareDim, height, roundedPartHeight);
+
+      translate(v=[cornerSquareDim, wallThickness, -topThickness])
+        cube(size=[width-2*cornerSquareDim, depth-2*wallThickness, height]);
+    }
+  }
+}
+
+// Negative and centered on xy. Aligned with z=0 downwards
+module _lugAndMagnet() {
+  slack = 0.3;
+  vSlack = 0.1;
+  // lug
+  translate(v=[0,0,-2.5])
+  cube(size=[10+slack, 10+slack, 5+vSlack], center=true);
+
+  // hole for magnet, no tolerance on
+  translate(v=[0,0,-(5+vSlack+1.7)])
+  cylinder(d=6+slack, h=1.7+vSlack);
+}
+
+module baseBody() {
+  difference() {
+    _bodySil(_width, _depth, _height, 4, 5, 2);
+
+    _mid = [_width / 2, _depth / 2, _height];
+
+    union() {
+
+      for (i = mirror4XY(midpoint = _mid, offsetX = (_width / 2) - 15, offsetY = (_depth / 2) - 10)) {
+        translate(v = i)
+          _lugAndMagnet();
+      }
+
+      screwHolePositions = concat(
+      mirror4XY(midpoint = _mid, offsetX = (_width / 2) - 25, offsetY = (_depth / 2) - 20),
+      mirror4XY(midpoint = _mid, offsetX = (_width / 2) - 15, offsetY = (_depth / 2) - 20),
+      mirror4XY(midpoint = _mid, offsetX = (_width / 2) - 25, offsetY = (_depth / 2) - 10)
+      );
+
+      for (i = screwHolePositions) {
+        translate(v = i) {
+          cylinder(r = m3RadiusSlacked, h = inf, center = true);
+
+        }
+      }
+
+    }
+  }
+}
 
 
+difference() {
+  baseBody();
+
+  union() {
+    minkowski() {
+      translate(v = [(_width - 130) / 2, (_depth - 150) / 2, - inf / 2])
+        cube(size = [130, 150, inf]);
+
+      cylinder(r = 5);
+    }
+  }
+}
+

cases/rack/rackCase.scad

@@ -298,7 +298,7 @@ module frontPlateAligned() {
       frontPlate();
 
     union() {
-      // lugs
+      // lugs TODO not recessed enough!!
       translate(v=[-0.05,-(1.5+boxFrontThickness),-0.05])
         cube(size=[4+0.1,2,4+0.1]);
 

cases/rack2/config.scad

@@ -0,0 +1,32 @@
+/*
+   case-files v2
+   This file contains parameters used for declaring/generating a customized rack frame.
+
+   - All dimensions are in millimetres (mm) unless stated otherwise.
+   - A "_N" appended to a module is meant to denote that this module is a negative volume, and should only be used to
+     substract from other volumes.
+*/
+
+// Maximum width for rackmount units. Change this according your max expected enclosure width.
+// Changing this will directly affect the required build volume.
+maxUnitWidth = 200;
+
+// Maximum (recommended) unit depth. There technically isn't a max unit depth because there's no physical bound on
+// how far a rack unit can extrude back. This parameter basically controls the distance between the front of the front
+// rails and the back of the back rails. Changing this will directly affect the required build volume.
+maxUnitDepth = 200;
+
+// Vertical distance between the midpoint of adjacent screws mounts. Affects build volume.
+screwDiff = 10;
+
+// Number screw slots on the main rail. Affects build volume.
+numRailScrews = 20;
+
+// Screw type used for rackmount units. See screws.scad.
+railMainScrewType = "m4";
+
+// Screw type used to affix side rails.
+railSideMountScrewType = "m4";
+
+// Screw type used for constructing the actual rack frame.
+rackScrewType = "m3";

cases/rack2/mainRail.scad

@@ -0,0 +1,121 @@
+include <./config.scad>
+include <./screws.scad>
+
+// Distance between the middle of a screw mount and the rail's vertical edges
+railScrewHoleToInnerEdge = 5;
+railScrewHoleToOuterEdge = 5;
+
+// Distance between the midpoint of the rail screw holes.
+rackMountScrewWidth = maxUnitWidth + 2*railScrewHoleToInnerEdge;
+
+railFrontThickness = 6; // Make sure that the nuts for the chosen screw type can slot within the front face
+railSideMountThickness = 2.5;
+railOtherThickness = 2.5;
+
+
+// Extra spacing for the rack unit screws.
+frontScrewSpacing = 8;
+
+/* Small horizontal planes at the top and bottom of the main rails. Used so we can fasten the rail to the frame
+   Note that this value is also used for a depression at the bottom/top of the frame for aligning the rail */
+railFootThickness = 3;
+
+railTotalHeight = screwDiff * (numRailScrews+1) + 2*railFootThickness;
+
+
+sideSupportExtraSpace = 2;
+sideSupportScrewHoleToFrontEdge = 5;
+sideSupportScrewHoleToBackEdge = 4.5;
+sideSupportDepth = sideSupportScrewHoleToBackEdge + sideSupportScrewHoleToFrontEdge;
+
+frontFaceWidth = railScrewHoleToInnerEdge + railScrewHoleToOuterEdge;
+
+
+module _frontRailSegment() {
+    difference() {
+        cube(size=[frontFaceWidth, railFrontThickness, railTotalHeight]);
+
+        for (i=[1:numRailScrews]) {
+            translate(v=[railScrewHoleToOuterEdge, railFrontThickness/2, i*screwDiff + railFootThickness])
+                rotate(a=[90,0,0])
+                    m4HexNutPocketNegative();
+        }
+    }
+}
+
+module _connectingLBracketRailSegment() {
+
+    difference() {
+        cube(size = [railOtherThickness, frontScrewSpacing + railOtherThickness, railTotalHeight]);
+
+        union () {
+            translate(v=[0,4,railFootThickness + screwDiff / 2])
+                rotate(a=[0,90,0])
+                    cylinder(r=m3RadiusSlacked, h = 10, $fn=32, center=true);
+
+            translate(v=[0,4,railTotalHeight-(railFootThickness + screwDiff / 2)])
+                rotate(a=[0,90,0])
+                    cylinder(r=m3RadiusSlacked, h = 10, $fn=32, center=true);
+        }
+    }
+
+    translate(v=[0, frontScrewSpacing + railOtherThickness, 0])
+    rotate(a=[0,0,270])
+        cube(size=[railOtherThickness, frontFaceWidth - sideSupportExtraSpace, railTotalHeight]);
+}
+
+
+module _sideSupportSegment() {
+
+    difference() {
+        cube(size=[sideSupportDepth, railSideMountThickness, railTotalHeight]);
+
+        for (i=[1:numRailScrews]) {
+            translate(v=[sideSupportScrewHoleToFrontEdge, railFrontThickness/2, i*screwDiff + railFootThickness])
+            rotate(a=[90,0,0])
+                    cylinder(r=m4RadiusSlacked, h=10, $fn=32);
+        }
+    }
+
+}
+
+module _railFeet() {
+
+    difference() {
+        cube(size = [frontFaceWidth - sideSupportExtraSpace, sideSupportDepth, railFootThickness]);
+
+        hull() {
+            translate(v = [1.5, 5, 0])
+                cylinder(r = m3RadiusSlacked, h = 10, $fn = 32);
+
+            translate(v = [0, 5, 0])
+            cube(size=[0.1, m3RadiusSlacked*2, 10], center=true);
+        }
+    }
+}
+
+module mainRail() {
+    union() {
+
+        _frontRailSegment();
+
+        translate(v = [0, railFrontThickness, 0])
+            _connectingLBracketRailSegment();
+
+        translate(v = [frontFaceWidth-sideSupportExtraSpace, railFrontThickness + railOtherThickness + frontScrewSpacing, 0])
+            rotate(a = [0, 0, 90])
+                _sideSupportSegment();
+
+
+        translate(v = [0, railFrontThickness + railOtherThickness + frontScrewSpacing, 0]) {
+            _railFeet();
+
+            translate(v = [0, 0, railTotalHeight-railFootThickness])
+                _railFeet();
+        }
+    }
+}
+
+mainRail();
+
+echo("Total Rail Height = ", railTotalHeight);

cases/rack2/screws.scad

@@ -0,0 +1,113 @@
+
+/* Some common screw dimensions */
+
+
+inf = 400; // basically infinity
+
+/********************************************************************************/
+// M3 dimensions
+
+m3HoleRadiusSlack = 0.15;
+m3Diameter = 3.0;
+m3Radius = m3Diameter/2.0;
+
+m3RadiusSlacked = m3Radius + m3HoleRadiusSlack;
+
+// legacy TODO: replace
+m3ptr = m3RadiusSlacked;
+
+// NUTS!
+m3HexNutWidthAcrossFlats = 5.41;
+m3HexNutWidthAcrossCorners = FtoG(m3HexNutWidthAcrossFlats);
+
+m3HexNutThickness = 2.18;
+
+module m3HexNutPocketNegative() {
+  hexNutPocketNegative(m3RadiusSlacked,
+                       m3HexNutWidthAcrossCorners/2 + 0.1,
+                       m3HexNutThickness + 0.2);
+}
+
+
+// TODO: remove test
+
+*difference() {
+  cube(size=[8,12,5], center=true);
+
+  rotate(a=[0,0,20])
+  m3HexNutPocketNegative();
+}
+
+*m3HexNutPocketNegative();
+
+
+/********************************************************************************/
+// M4 dimensions
+
+m4HoleRadiusSlack = 0.15;
+m4Diameter = 4.0;
+m4Radius = m4Diameter/2.0;
+m4RadiusSlacked = m4Radius + m4HoleRadiusSlack;
+
+m4HexNutWidthAcrossFlats = 6.89;
+m4HexNutWidthAcrossCorners = FtoG(m4HexNutWidthAcrossFlats);
+
+m4HexNutThickness = 3.07;
+
+module m4HexNutPocketNegative() {
+  hexNutPocketNegative(m4RadiusSlacked,
+                       m4HexNutWidthAcrossCorners/2 + 0.1,
+                       m4HexNutThickness + 0.2);
+}
+
+
+// TODO: remove test
+
+*difference() {
+  translate(v=[0,1,0])
+  cube(size=[10,12,6], center=true);
+
+  rotate(a=[0,0,20])
+  m4HexNutPocketNegative();
+}
+
+*m4HexNutPocketNegative();
+
+/********************************************************************************/
+
+// Convert a regular hexagon widthAcrossFlats to widthAcrossCorners
+function FtoG(widthAcrossFlats) = widthAcrossFlats * (2/sqrt(3));  
+
+// Convert a regular hexagon widthAcrossCorners to widthAcrossFlats
+function GtoF(widthAcrossCorners) =  widthAcrossCorners * (sqrt(3)/2);
+
+
+module hexNutPocketNegative(
+  innerRadius,
+  widthAcrossCorners,
+  thickness)
+{
+
+  union() {
+
+    hull() {
+      // hexagonal cylinder representing where the nut should fit
+      cylinder(r=widthAcrossCorners, h=thickness, center=true, $fn=6);
+
+      // negative volume for sliding in the nut
+      translate(v=[inf,0,0])
+      cylinder(r=widthAcrossCorners, h=thickness, center=true, $fn=6);
+    }
+
+    // negative volume for screw lead
+    translate(v=[0,0,-10])
+    cylinder(r=innerRadius, h = inf, $fn=32);
+
+    hull() {
+     translate(v=[inf,0,0])
+       cylinder(r=innerRadius, h = inf, $fn=32);
+     cylinder(r=innerRadius, h = inf, $fn=32);
+    }
+  }
+}
+

cases/rockpro/case.scad~

@@ -1,214 +0,0 @@
-// test for screw tolerances
-
-include <./rockpro.scad>;
-
-include <../power/src/base.scad>;
-$fn = 128;
-outerD = 4.65;
-
-innerD = 2.93;
-
-
-
-*difference() {
-    cube(size=[10,50,10]);
-    union() {
-        translate(v=[5,10,-1])
-        cylinder(h=30,r=innerD/2-0.2);
-        
-        translate(v=[5,25,-1])
-        cylinder(h=30,r=innerD/2);
-        
-        translate(v=[5,40,-1])
-        cylinder(h=30,r=innerD/2+0.2);
-    }
-}
-
-
-
-module caseOuter() {
-    rotate(a=[90,0,0])
-    minkowski() {
-        cube(size=[80,40,195], center=true);
-        cylinder(h=0.00000000001, r=10);
-    }
-}
-
-module caseInner() {
-    translate(v=[0,0,2])
-    rotate(a=[90,0,0])
-    minkowski() {
-        cube(size=[81.5,47,195+0.01], center=true);
-        *cylinder(h=0.00000000001, r=5);
-    }
-}
-
-
-module hgill(i) {
-  minkowski() {
-    *sphere(r=2);
-              translate(v=[0,i*10,5])
-              rotate(a=[30,0,0])
-              cube(size=[200, 4, 30], center=true);
-          }
-    }
-
-module caseShell() {
-    difference() {
-        caseOuter();
-
-        union() {
-          caseInner();
-
-          // side perforations
-          for (i=[-7:7]) {
-              hgill(i=i);
-          }
-
-          // top perforations
-          for (i=[-3:3]) {
-            translate(v=[0,i*20,50])
-            cube(size=[75,10,60], center=true);
-          }
-
-          // bottom perforations
-          for (i=[2:4]) {
-            translate(v=[0,i*20,-20])
-            cube(size=[60,8,50], center=true);
-          }
-
-          for (i=[-4:0]) {
-            translate(v=[0,i*20,-20])
-            cube(size=[60,8,50], center=true);
-          }
-          
-        }
-    }
-}
-
-
-module faceMountDiffs() {
-translate(v=[45,0,20])
-rotate(a=[90,0,0])
-cylinder(r=innerD/2,h=300, center=true);
-
-translate(v=[45,0,-20])
-rotate(a=[90,0,0])
-cylinder(r=innerD/2,h=300, center=true);
-
-translate(v=[-45,0,-20])
-rotate(a=[90,0,0])
-cylinder(r=innerD/2,h=300, center=true);
-
-translate(v=[-45,0,20])
-rotate(a=[90,0,0])
-cylinder(r=innerD/2,h=300, center=true);
-}
-
-
-module caseWithMountHoles() {
-  difference() {
-
-    union() {
-      caseShell();
-
-      translate(v=[-35, 25,-27.5])
-      rotate(a=[0,0,-90])
-      rockProMountPoints(6, 3.8, 64, false);
-    }
-
-    union() {
-      translate(v=[-35, 25,-27.5])
-      rotate(a=[0,0,-90])
-      rockProMountPoints(6, innerD/2, 64, false);
-
-      faceMountDiffs();
-    }
-  }
-}
-
-*caseWithMountHoles();
-
-
-module bottomTray() {
-difference() {
-
-union() {
-intersection() {
-  caseWithMountHoles();
-  translate(v=[0,0,-115])
-  cube(size=[500,500,200], center=true);
-}
-
-translate(v=[-45.5,0,-15])
-rotate(a=[90,90,0])
-joinTriangle(185);
-
-translate(v=[45.5,0,-15])
-rotate(a=[90,90,0])
-joinTriangle(185);
-}
-
-  // bottom lugs
-  union() {
-    translate(v=[-40,-90,-29])
-    cube(size=[10.2,10.2,2.5], center=true);
-
-    translate(v=[40,-90,-29])
-    cube(size=[10.2,10.2,2.5],center=true);
-
-    translate(v=[40,90,-29])
-    cube(size=[10.2,10.2,2.5],center=true);
-
-    translate(v=[-40,90,-29])
-    cube(size=[10.2,10.2,2.5],center=true);
-  }
-}
-}
-
-
-module topTray() {
-  difference () {
-    union() {
-      difference() {
-        caseWithMountHoles();
-        translate(v=[0,0,-115])
-          cube(size=[500,500,200], center=true);
-      }
-    }
-    // bottom lugs
-    union() {
-      translate(v=[-40,-90,29])
-        cube(size=[10.2,10.2,2.5], center=true);
-
-      translate(v=[40,-90,29])
-        cube(size=[10.2,10.2,2.5],center=true);
-
-      translate(v=[40,90,29])
-        cube(size=[10.2,10.2,2.5],center=true);
-
-      translate(v=[-40,90,29])
-        cube(size=[10.2,10.2,2.5],center=true);
-
-      
-      
-      translate(v=[-45.5,0,-15])
-        rotate(a=[90,90,0])
-        scale(v=[1,0.9,1])
-        joinTriangle(300);
-
-      translate(v=[45.5,0,-15])
-        rotate(a=[90,90,0])
-        scale(v=[1,0.9,1])
-        joinTriangle(300);
-    }
-  }
-}
-
-topTray();
-
-// TODO make sure rail works!!!
-
-
-scale(v=[1,0.9,1])
-*joinTriangle(10);

cases/rockpro/newcase.scad~

@@ -1,66 +0,0 @@
-
-include <./rockpro.scad>;
-
-include <../power/src/base.scad>;
-$fn = 128;
-outerD = 4.65;
-
-innerD = 2.93;
-
-
-
-
-
-module caseOuter() {
-    rotate(a=[90,0,0])
-    minkowski() {
-        cube(size=[80,40,195], center=true);
-        cylinder(h=0.00000000001, r=10);
-    }
-}
-
-module caseInner() {
-    translate(v=[0,0,2])
-    rotate(a=[90,0,0])
-    minkowski() {
-        cube(size=[81.5,47,195+0.01], center=true);
-        *cylinder(h=0.00000000001, r=5);
-    }
-}
-
-
-module caseShell() {
-    difference() {
-        caseOuter();
-
-        union() {
-          caseInner();
-
-          // side perforations
-          for (i=[-7:7]) {
-              hgill(i=i);
-          }
-
-          // top perforations
-          for (i=[-3:3]) {
-            translate(v=[0,i*20,50])
-            cube(size=[75,10,60], center=true);
-          }
-
-          // bottom perforations
-          for (i=[2:4]) {
-            translate(v=[0,i*20,-20])
-            cube(size=[60,8,50], center=true);
-          }
-
-          for (i=[-4:0]) {
-            translate(v=[0,i*20,-20])
-            cube(size=[60,8,50], center=true);
-          }
-          
-        }
-    }
-}
-
-
-caseShell();

cases/sinusoid.scad

@@ -25,15 +25,15 @@ module sineWave(length, resolution, amplitudeFunction, period, shift) {
         idx_curr = i * dx;
         hull() {
             translate(v = [idx_prev, amplitudeFunction(idx_prev) * sinR(p * idx_prev + shift), 0])
-                cube(size = [0.1, 1, 1]);
+                cube(size = [0.1, 2, 2]);
 
             translate(v = [idx_curr, amplitudeFunction(idx_curr) * sinR(p * idx_curr + shift), 0])
-                cube(size = [0.1, 1, 1]);
+                cube(size = [0.1, 2, 2]);
 
             translate(v = [idx_curr, -10, 0])
-                cube(size=[0.1,1,1]);
+                cube(size=[0.1,2,2]);
             translate(v = [idx_prev, -10, 0])
-                cube(size=[0.1,1,1]);
+                cube(size=[0.1,2,2]);
         }
     }
 }
@@ -47,15 +47,15 @@ module sineWaveHull(length, resolution, amplitudeFunction, period, shift, hullDi
         idx_curr = i * dx;
         hull() {
             translate(v = [idx_prev, amplitudeFunction(idx_prev) * sinR(p * idx_prev + shift), 0])
-                cube(size = [0.1, 1, 1]);
+                cube(size = [0.1, 2, 2]);
 
             translate(v = [idx_curr, amplitudeFunction(idx_curr) * sinR(p * idx_curr + shift), 0])
-                cube(size = [0.1, 1, 1]);
+                cube(size = [0.1, 2, 2]);
 
             translate(v = [idx_curr, -hullDiff, 0])
-                cube(size=[0.1,1,1]);
+                cube(size=[0.1,2,2]);
             translate(v = [idx_prev, -hullDiff, 0])
-                cube(size=[0.1,1,1]);
+                cube(size=[0.1,2,2]);
         }
     }
 }