desk-controls/openscad/enclosure.scad

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;
// Spacing between keys
key_distance = 0;
// With of a 1u keycap
key_width = 19.05;
// Width of key switch cutout
keyswitch_cutout_width = 14;

// Diameter of the dial, used for spacing
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
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;
    cube([plate_width, plate_height, plate_thickness]);
    translate([plate_margin, plate_margin, -1]) {
      // Dial cutouts
      translate([(dial_diameter - dial_base_width) / 2,
                 (dial_diameter - dial_base_height) / 2]) {
        union() {
          cube([dial_base_width, dial_base_height, plate_thickness + 2]);
          translate([(dial_base_width - dial_pin_width) / 2, - dial_pin_length]) {
            // Provide a 0.5mm-thick lip to hide the pins
            cube([dial_pin_width, dial_base_height + dial_pin_length, plate_thickness + 2 - 1.5]);
          }
        }
      }
      // Key switch cutouts
      offset_y = dial_diameter <= key_width ? 0 : (dial_diameter - key_width) / 2;
      translate([dial_diameter + dial_distance, offset_y]) {
        translate([keyswitch_cutout_offset, keyswitch_cutout_offset + offset_y]) {
          xspread(spacing=key_width + key_distance, n=keys, sp=[0,0,0]) {
            cube([keyswitch_cutout_width, keyswitch_cutout_width, plate_thickness + 2]);
          }
        }
      }
    }
  }
}

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]);
    }
    translate([case.x + case_thickness * 1.5,
                case.y / 2 + case_thickness,
                case_thickness + (usb_thickness / 2)])
      rotate([90,0,90])
      slot(l=12, d=7, h=case_thickness * 2);
  }

  // Wemos D1 Mini clip
  color("red", 0.1)
    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]);
  }

  // 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();
    }
  }
}