bsb/case/case.scad

   1 // x,y is [0,0] at near left PCB screw
   2 // z=0 is the bottom of the PCB
   3
   4 wall_thickness = 1.8;
   5 front_panel_thickness = 1.35;
   6
   7 // Measured between PCB screws
   8 pcb_width = 66;         // x
   9 pcb_length = 58.4;      // y
  10
  11 // From screws to PCB edges
  12 pcb_left = 5;
  13 pcb_right = 5;
  14 pcb_front = 5.2;
  15 pcb_back = 10;
  16 pcb_thickness = 1.5;
  17
  18 // Interior dimensions relative to z=0
  19 box_height = 26;
  20 box_depth = 4;
  21
  22 // Screw dimensions
  23 screw_inside_diam = 2.5;
  24 screw_outside_diam = 3.2;
  25 screw_head_diam = 6;
  26 screw_head_height = 1.4;
  27 screw_length = 14;              // really 12, but make the hole deeper
  28
  29 // Screw holders
  30 holder_size = 3*2.5;
  31
  32 // Cable hole
  33 cable_x = 9;
  34 cable_z = 6.5;
  35 cable_diameter = 8;
  36
  37 // Holes in front panel
  38 ref_x = pcb_width + 3.8;
  39 led1_x = ref_x - 63;
  40 led2_x = ref_x - 45;
  41 led3_x = ref_x - 40;
  42 led4_x = ref_x - 35;
  43 led_z = 6.2;
  44 led_diameter = 3.1;
  45 usb_left = ref_x - 26;
  46 usb_right = ref_x - 17;
  47 usb_bottom = 13.5;
  48 usb_top = 17.5;
  49
  50 // Lid
  51 lid_smaller = 0.2;
  52 lid_left = pcb_left - lid_smaller;
  53 lid_right = pcb_right - lid_smaller;
  54 lid_front = pcb_front - lid_smaller;
  55 lid_back = pcb_back - lid_smaller;
  56 lid_thickness = 1.8;
  57 text_depth = 0.8;
  58
  59 over = 0.1;
  60 $fn = 50;
  61
  62 module led_hole() {
  63         rotate([-90, 0, 0])
  64                 cylinder(h = front_panel_thickness + 2*over, d = led_diameter);
  65 }
  66
  67 module screw_holder() {
  68         translate([-holder_size/2, -holder_size/2, -box_depth - over])
  69                 cube([holder_size, holder_size, box_depth + over]);
  70 }
  71
  72 module screw_hole() {
  73         translate([0, 0, -box_depth - wall_thickness - over])
  74                 union() {
  75                         cylinder(h = box_depth + wall_thickness + 2*over, d = screw_outside_diam);
  76                         cylinder(h = screw_head_height, d1 = screw_head_diam, d2 = screw_outside_diam);
  77                 }
  78 }
  79
  80 module bottom_base() {
  81         union() {
  82                 difference() {
  83                         // Exterior
  84                         translate([-wall_thickness - pcb_left, -front_panel_thickness - pcb_front, -wall_thickness - box_depth])
  85                                 cube([wall_thickness + pcb_left + pcb_width + pcb_right + wall_thickness,
  86                                       front_panel_thickness + pcb_front + pcb_length + pcb_back + wall_thickness,
  87                                       wall_thickness + box_depth + box_height]);
  88
  89                         // Interior
  90                         translate([-pcb_left, -pcb_front, -box_depth])
  91                                 cube([pcb_left + pcb_width + pcb_right, pcb_front + pcb_length + pcb_back, box_depth + box_height + over]);
  92
  93                         // USB connector hole
  94                         translate([usb_left, -front_panel_thickness - pcb_front - over, usb_bottom])
  95                                 cube([usb_right - usb_left, front_panel_thickness + 2*over, usb_top - usb_bottom]);
  96
  97                         // LED holes
  98                         translate([led1_x, -pcb_front - front_panel_thickness - over, led_z])
  99                                 led_hole();
 100                         translate([led2_x, -pcb_front - front_panel_thickness - over, led_z])
 101                                 led_hole();
 102                         translate([led3_x, -pcb_front - front_panel_thickness - over, led_z])
 103                                 led_hole();
 104                         translate([led4_x, -pcb_front - front_panel_thickness - over, led_z])
 105                                 led_hole();
 106
 107                         // BSB cable hole
 108                         translate([cable_x, pcb_length + pcb_back - over, cable_z])
 109                                 rotate([-90, 0, 0])
 110                                         cylinder(h = wall_thickness + 2*over, d = cable_diameter);
 111                 }
 112         }
 113 }
 114
 115 module bottom() {
 116         difference() {
 117                 union() {
 118                         bottom_base();
 119
 120                         // Screw holder
 121                         screw_holder();
 122                         translate([pcb_width, 0, 0]) screw_holder();
 123                         translate([0, pcb_length, 0]) screw_holder();
 124                         translate([pcb_width, pcb_length, 0]) screw_holder();
 125                 }
 126
 127                 // Screw holes
 128                 screw_hole();
 129                 translate([pcb_width, 0, 0]) screw_hole();
 130                 translate([0, pcb_length, 0]) screw_hole();
 131                 translate([pcb_width, pcb_length, 0]) screw_hole();
 132         }
 133 }
 134
 135 module lid_text(overshoot = 0) {
 136         translate([pcb_width / 2, 10, -text_depth/2])
 137         rotate(0)
 138         scale([0.8, 0.8, 1])
 139                 linear_extrude(text_depth + overshoot, center = true)
 140                 text("USB – BSB", font = "Liberation Serif", halign="center");
 141 }
 142
 143 module lid_screw_hole() {
 144         translate([0, 0, -box_height + pcb_thickness])
 145                 difference() {
 146                         translate([-holder_size/2, -holder_size/2, 0])
 147                                 cube([holder_size, holder_size, box_height - pcb_thickness - lid_thickness + over]);
 148                         translate([0, 0, -over])
 149                                 cylinder(h = screw_length - pcb_thickness - box_depth - wall_thickness + over, d = screw_inside_diam);
 150                 }
 151 }
 152
 153 module lid() {
 154         difference() {
 155                 union() {
 156                         translate([-lid_left, -lid_front, -lid_thickness])
 157                                 cube([lid_left + pcb_width + lid_right, lid_front + pcb_length + lid_back, lid_thickness]);
 158                         lid_screw_hole();
 159                         translate([pcb_width, 0, 0]) lid_screw_hole();
 160                         translate([0, pcb_length, 0]) lid_screw_hole();
 161                         translate([pcb_width, pcb_length, 0]) lid_screw_hole();
 162                 }
 163
 164                 // Text
 165                 lid_text(over);
 166         }
 167 }
 168
 169 module pcb() {
 170         translate([-pcb_left, -pcb_front, 0])
 171                 cube([pcb_left + pcb_width + pcb_right, pcb_front + pcb_length + pcb_back, pcb_thickness]);
 172 }
 173
 174 // bottom();
 175 // color([1, 0, 1]) pcb();
 176 color([1, 0, 0]) translate([0, 0, box_height]) lid();
 177 // color([0, 0, 1]) translate([0, 0, box_height]) lid_text(0);