Design the case

openscad/enclosure.scad

@@ -1,11 +1,17 @@
 include <BOSL/constants.scad>
 use <BOSL/math.scad>
+use <BOSL/shapes.scad>
 use <BOSL/transforms.scad>
+include <wemos_d1_mini.scad>
 
 $fn = $preview ? 30 : 50;
 
+case_thickness = 3;
+wire_clearance = 10;
 plate_margin = 5;
 plate_thickness = 3;
+plate_depth = 3;
+plate_clearance = 0.3;
 
 // Number of key switches
 keys = 3;
@@ -20,6 +26,7 @@ keyswitch_cutout_width = 14;
 dial_diameter = 20;
 dial_base_width = 12.85;
 dial_base_height = 16.75;
+dial_base_protrusion = 1.5;
 dial_pin_width = 6;
 dial_pin_length = 3;
 // Space between the dial and the keypad
@@ -27,14 +34,14 @@ dial_distance = 5;
 
 keys_width = (key_width * keys) + (key_distance * (keys - 1));
 keys_height = key_width;
+plate_width = (plate_margin * 2) + dial_diameter + dial_distance + keys_width;
+plate_height = (plate_margin * 2) + max(dial_diameter, key_width);
 
 module support_plate() {
   difference() {
     keyswitch_cutout_offset = (key_width - keyswitch_cutout_width) / 2;
     dial_cutout_offset_x = (dial_diameter - dial_base_width) / 2;
     dial_cutout_offset_y = (dial_diameter - dial_base_height) / 2;
-    plate_width = (plate_margin * 2) + dial_diameter + dial_distance + keys_width;
-    plate_height = (plate_margin * 2) + max(dial_diameter, key_width);
     cube([plate_width, plate_height, plate_thickness]);
     translate([plate_margin, plate_margin, -1]) {
       // Dial cutouts
@@ -61,4 +68,108 @@ module support_plate() {
   }
 }
 
-support_plate();
+case = [(plate_margin * 2) + dial_diameter + dial_distance + keys_width + (plate_clearance * 2),
+        (plate_margin * 2) + max(dial_diameter, key_width) + (plate_clearance * 2),
+        wire_clearance + wemos_d1_mini.z + plate_depth];
+
+module case() {
+  difference() {
+    cuboid([case.x + case_thickness * 2,
+            case.y + case_thickness * 2,
+            case.z + case_thickness],
+           center=false,
+           fillet=2,
+           edges=EDGES_TOP + EDGES_Z_ALL);
+    translate([case_thickness,case_thickness, case_thickness]) {
+      cube([case.x, case.y, case.z + 1]);
+    }
+  }
+
+  // Wemos D1 Mini clip
+  color("red")
+    translate([case_thickness + case.x - wemos_d1_mini.y,
+               case_thickness + ((case.y - (wemos_d1_mini.x + 4)) / 2),
+               case_thickness]) {
+    difference() {
+      cube([wemos_d1_mini.y, wemos_d1_mini.x + 4,
+            wemos_d1_mini.z - esp_thickness + 2]);
+      translate([0,1, usb_thickness])
+        cuboid([wemos_d1_mini.y,
+                wemos_d1_mini.x + 2,
+                pcb_thickness + 2],
+               center=false,
+               chamfer=1,
+               edges=EDGES_X_ALL);
+      translate([0,2])
+        cube([wemos_d1_mini.y, wemos_d1_mini.x,
+              usb_thickness]);
+    }
+    translate([-3,wemos_d1_mini.x / 2 - 3])
+      cube([2,9,wemos_d1_mini.z - esp_thickness]);
+    // translate([case.x - wemos_d1_mini.y - 6, case.y / 2 - 2.5])
+    //   cube([5,5, case.z - plate_depth]);
+
+  }
+
+  // Supports
+  color("purple") {
+    // position within the bounds of the case
+    translate([case_thickness, case_thickness]) {
+      // position within the bounds of the support plate
+      translate([plate_clearance, plate_clearance]) {
+        // dial support pillar
+        // position in the center of the dial
+        translate([(plate_margin + dial_diameter / 2) - 2.5,
+                   (plate_margin + dial_diameter / 2) - 2.5])
+          cube([5, 5, case.z - plate_depth - dial_base_protrusion]);
+
+        // screw pillar
+        translate([plate_margin + dial_diameter + (dial_distance / 2),
+                   case.y / 2]) {
+          difference() {
+            cylinder(d=6,h=case.z - plate_depth);
+            cylinder(d=3,h=case.z - plate_depth);
+          }
+        }
+      }
+
+      cube([3,3, case.z - plate_depth]);
+      translate([0, case.y - 3])
+        cube([3,3, case.z - plate_depth]);
+
+      translate([case.x / 2, 0])
+        cube([3,3, case.z - plate_depth]);
+      translate([case.x / 2, case.y - 3])
+        cube([3,3, case.z - plate_depth]);
+
+      translate([case.x - 1.5, 0])
+        cube([1.5,1.5,case.z - plate_depth]);
+      translate([case.x - 1.5, case.y - 1.5])
+        cube([1.5,1.5,case.z - plate_depth]);
+
+      translate([1.5, case_thickness, case.z - plate_depth]) {
+
+      }
+    }
+  }
+}
+
+translate([-4, -4, 0]) {
+  case();
+  translate([case_thickness, case_thickness, case_thickness]) {
+    translate([plate_clearance,
+               plate_clearance,
+               case.z - plate_thickness - plate_depth]) {
+      color("yellow", 0.3) {
+        // support_plate();
+      }
+    }
+    color("white", 0.05)
+      translate([case.x - wemos_d1_mini.y,
+                 wemos_d1_mini.x + ((case.y - wemos_d1_mini.x) / 2),
+                 0])
+      rotate([0,0,-90]) {
+      // wemos_d1_mini();
+    }
+  }
+}

openscad/wemos_d1_mini.scad

@@ -0,0 +1,50 @@
+pcb_width = 25.3;
+pcb_height = 34.5;
+pcb_thickness = 1.25;
+
+usb_height = 5.2;
+usb_width = 7.75;
+usb_thickness = 2.6;
+usb_offset = 10;
+
+esp_height = 15;
+esp_width = 12;
+esp_thickness = 4.75;
+esp_offset_x = 7;
+esp_offset_y = 7.5;
+
+esp_board_thickness = 1;
+esp_board_height = 24.25;
+esp_board_width = 16;
+esp_board_offset = 5.25;
+
+wemos_d1_mini = [pcb_width,
+                 pcb_height,
+                 usb_thickness + pcb_thickness + esp_thickness];
+
+module wemos_d1_mini(box=false, box_alpha=0.4) {
+
+  union() {
+    color("blue")
+      translate([0,0,usb_thickness])
+      cube([pcb_width, pcb_height, pcb_thickness]);
+    translate([usb_offset, pcb_height - usb_height, 0])
+      color("silver")
+      cube([usb_width, usb_height, usb_thickness]);
+    translate([esp_board_offset,
+               0,
+               usb_thickness + pcb_thickness])
+      color("black")
+      cube([esp_board_width, esp_board_height, esp_board_thickness]);
+    translate([esp_offset_x,
+               esp_offset_y,
+               pcb_thickness + usb_thickness])
+      color("silver")
+      cube([esp_width, esp_height, esp_thickness]);
+  }
+
+  if (box) {
+    color("gold", box_alpha)
+      cube(wemos_d1_mini);
+  }
+}