stmbl/hw/tools/sheet_metal_case.scad

include <stmbl.scad>;
translate([88, 0, - 52.25 - 8 - 2.5 - 1.6]) stmbl();


wall_t = 1;
gap_w = 1;
bend_a = 0.0;
bridge_w = 1.5;
slot_l = 25;
bend = 1;
corner_r = 0.5;
c = "grey";
space = 0.25;
pcb_t = 1.6;
heatsink_l = 104.5;
heatsink_w = 46;
case_h = 69;
led_r = 0.5;
$fn = 20;




module bend_gap(l){
  l1 = l - gap_w - bridge_w;
  num_slots = max(floor(l1 / slot_l), 1);
  slot_l1 = l1 / num_slots;
  color(c) translate([0, 0, -1]){
    cylinder(r = gap_w / 2, h = wall_t + 2);
    translate([l, 0, 0]) cylinder(r = gap_w / 2, h = wall_t + 2);
    for(a = [0:num_slots - 1]){
      translate([a * slot_l1, 0, 0]){
        hull(){
          translate([gap_w + bridge_w, 0, 0]) cylinder(r = gap_w / 2, h = wall_t + 2);
          translate([slot_l1, 0, 0]) cylinder(r = gap_w / 2, h = wall_t + 2);
        }
      }
    }
  }
}

module up(){
  color(c) difference(){
    hull(){
      translate([corner_r, corner_r, 0]) cylinder(r = corner_r, h = wall_t);
      translate([heatsink_l - corner_r, corner_r, 0]) cylinder(r = corner_r, h = wall_t);
      translate([heatsink_l - corner_r, heatsink_w - corner_r, 0]) cylinder(r = corner_r, h = wall_t);
      translate([corner_r, heatsink_w - corner_r, 0]) cylinder(r = corner_r, h = wall_t);
    }
    translate([64.5, 4.75, -1]) hull(){ // usb
      translate([-3 - space, 0, 0]) cylinder(r = 1.5 + space, h = wall_t + 2);
      translate([3 + space, 0, 0]) cylinder(r = 1.5 + space, h = wall_t + 2);
    }
    translate([15.5, 6 - 0.5, -1]) cylinder(r = led_r + space, h = wall_t + 2); // led
    translate([26, 6 - 0.5, -1]) cylinder(r = led_r + space, h = wall_t + 2); // led
    translate([44, 6 - 0.5, -1]) cylinder(r = led_r + space, h = wall_t + 2); // led
    translate([49.25, 6 - 0.5, -1]) cylinder(r = led_r + space, h = wall_t + 2); // led
    translate([54.5, 6 - 0.5, -1]) cylinder(r = led_r + space, h = wall_t + 2); // led
    translate([9.5 - space, 6 + pcb_t - space, -1]) cube([31.5 + space * 2, 7 + space * 2, wall_t + 2]); // ain + cmd
    translate([41.75 - space, 6 + pcb_t - space, -1]) cube([15.25 + space * 2, 5 + space * 2, wall_t + 2]); // io
  }
}

module front_left(){
  color(c) difference(){
    union(){
      hull(){
        translate([corner_r, -corner_r, 0]) cylinder(r = corner_r, h = wall_t);
        translate([6 + pcb_t - space - corner_r, -corner_r, 0]) cylinder(r = corner_r, h = wall_t);
        translate([6 + pcb_t - space - corner_r, -52.25 - 4 - 3 + corner_r, 0]) cylinder(r = corner_r, h = wall_t);
        translate([corner_r, -52.25 - 4 - 3 + corner_r, 0]) cylinder(r = corner_r, h = wall_t);
      }
      *translate([0, -51 - space, 0]) hull(){
        translate([corner_r, -corner_r, 0]) cylinder(r = corner_r, h = wall_t);
        translate([heatsink_w - 23.5 - pcb_t - corner_r, -corner_r, 0]) cylinder(r = corner_r, h = wall_t);
        translate([heatsink_w - 23.5 - pcb_t - corner_r, -1.25 - 4 - 3 + space + corner_r, 0]) cylinder(r = corner_r, h = wall_t);
        translate([corner_r, -1.25 - 4 - 3 + space + corner_r, 0]) cylinder(r = corner_r, h = wall_t);
      }
    }
    *translate([45 / 2, -52.25 - 45 / 2, -1]) cylinder(r = 45 / 2, h = wall_t + 2);
    translate([4.4, -52.25 - 4, -1]) cylinder(r = 4 / 2 + space, h = wall_t + 2); // m4
  }
}

module front_right(){
    color(c) difference(){
      union(){
        hull(){
          translate([corner_r, corner_r, 0]) cylinder(r = corner_r, h = wall_t);
          translate([23.5 + pcb_t - space - corner_r, corner_r, 0]) cylinder(r = corner_r, h = wall_t);
          translate([23.5 + pcb_t - space - corner_r, 52.25 - corner_r, 0]) cylinder(r = corner_r, h = wall_t);
          translate([corner_r, 52.25 - corner_r, 0]) cylinder(r = corner_r, h = wall_t);
        }
        hull(){
          translate([corner_r, corner_r, 0]) cylinder(r = corner_r, h = wall_t);
          translate([6 + pcb_t - space - corner_r, corner_r, 0]) cylinder(r = corner_r, h = wall_t);
          translate([6 + pcb_t - space - corner_r, 52.25 + 4 + 3 - corner_r, 0]) cylinder(r = corner_r, h = wall_t);
          translate([corner_r, 52.25 + 4 + 3 - corner_r, 0]) cylinder(r = corner_r, h = wall_t);
        }
        
      }
      *translate([45 / 2, 52.25 + 45 / 2, -1]) cylinder(r = 45 / 2, h = wall_t + 2);
      translate([4.4, 52.25 + 4, -1]) cylinder(r = 4 / 2 + space, h = wall_t + 2); // m4
  }
}

module back_left(){
  color(c) difference(){
    hull(){
      translate([-corner_r, -corner_r, 0]) cylinder(r = corner_r, h = wall_t);
      translate([-6 - pcb_t - 7 + corner_r, -corner_r, 0]) cylinder(r = corner_r, h = wall_t);
      translate([-6 - pcb_t - 7 + corner_r, -case_h + corner_r, 0]) cylinder(r = corner_r, h = wall_t);
      translate([-corner_r, -case_h + corner_r, 0]) cylinder(r = corner_r, h = wall_t);
    }
    translate([-6 - pcb_t + space, - 3.75 + space, -1]) rotate([0, 0, 180]) cube([7 + space * 3, 31.5 + space * 2, wall_t + 2]); // 24V + out
    translate([0, - 46.75 + space, -1]) rotate([0, 0, 180]) cube([28.25 + space * 2, 8 + space * 2, wall_t + 2]); // uvw
    translate([-3.14, - 46.75 + space + 3, -1]) rotate([0, 0, 180]) cube([28.25 - 3.14 * 2, 3 + space, wall_t + 2]); // uvw
    translate([-6 + 0.5, -8 + space, -1]) cylinder(r = led_r + space, h = wall_t + 2); // led
    translate([-6 + 0.5, -17 + space, -1]) cylinder(r = led_r + space, h = wall_t + 2); // led
    translate([-6 + 0.5, -24 + space, -1]) cylinder(r = led_r + space, h = wall_t + 2); // led
    translate([-6 + 0.5, -31 + space, -1]) cylinder(r = led_r + space, h = wall_t + 2); // led
    translate([-5, -case_h + 2.6, -1]) cylinder(r = 1.5 + space, h = wall_t + 2); // m3
  }
}

module back_right(){
  color(c) translate([0, case_h, 0]) difference(){
    hull(){
      translate([-corner_r, -corner_r, 0]) cylinder(r = corner_r, h = wall_t);
      translate([-heatsink_w + 6 + pcb_t + 7 + corner_r + space, -corner_r, 0]) cylinder(r = corner_r, h = wall_t);
      translate([-heatsink_w + 6 + pcb_t + 7 + corner_r + space, -case_h + corner_r, 0]) cylinder(r = corner_r, h = wall_t);
      translate([-corner_r, -case_h + corner_r, 0]) cylinder(r = corner_r, h = wall_t);
    }
    translate([-heatsink_w + 28.25 + space, -case_h + 46.75 + space + 8, -1]) rotate([0, 0, 180]) cube([28.25 + space * 2, 8 + space * 2, wall_t + 2]); // uvw
    translate([-17.75 - 3.14,-case_h + 46.75, -1]) rotate([0, 0, 180]) cube([28.25 - 3.14 * 2, 3 + space, wall_t + 2]); // uvw
    translate([0,-case_h + 46.75 + 8 + space, -1]) rotate([0, 0, 180]) cube([9 + space, 7 + space * 2, wall_t + 2]); // uvw
    translate([-23.5,-case_h + 46.75 + 8  + pcb_t + 0.5, -1]) cylinder(r = led_r + space, h = wall_t + 2); // led
    translate([-5, -2.6, -1]) cylinder(r = 1.5 + space, h = wall_t + 2); // m3
  }
}


module left(){
  translate([0, -case_h, 0]) color(c) difference(){
    hull(){
      translate([corner_r, corner_r, 0]) cylinder(r = corner_r, h = wall_t);
      translate([heatsink_l - corner_r, corner_r, 0]) cylinder(r = corner_r, h = wall_t);
      translate([heatsink_l - corner_r, case_h - corner_r, 0]) cylinder(r = corner_r, h = wall_t);
      translate([corner_r, case_h - corner_r, 0]) cylinder(r = corner_r, h = wall_t);
    }
  }
}

module right(){
  translate([0, case_h, 0]) left();
}


module case(){
  difference(){
    up();
    bend_gap(heatsink_l);
    translate([0, heatsink_w, 0]) bend_gap(heatsink_l);
  }

  rotate([bend * 90, 0, 0]) {
    difference(){
      left();
      bend_gap(heatsink_l);
      rotate([0, 0, -90]) bend_gap(46.75 - space);
      translate([0, -case_h, 0]) rotate([0, 0, 90]) bend_gap(case_h - 46.75 - 8 - space);
      translate([heatsink_l, 0, 0]) rotate([0, 0, -90]) bend_gap(52.25 + 4 + 3);
    }
    rotate([0, -bend * 90, 0]) difference(){
      back_left();
      rotate([0, 0, -90]) bend_gap(46.75 - space);
      translate([0, -case_h, 0]) rotate([0, 0, 90]) bend_gap(case_h - 46.75 - 8 - space);
    }
    translate([heatsink_l, 0, 0]) rotate([0, bend * 90, 0]) difference(){
      front_left();
      rotate([0, 0, -90]) bend_gap(52.25 + 4 + 3);
    }
  }



  translate([0, heatsink_w, 0]) rotate([-bend * 90, 0, 0]) {
    difference(){
      right();
      bend_gap(heatsink_l);
      rotate([0, 0, 90]) bend_gap(46.75 + 8 - 7 - space);
      translate([heatsink_l, 0, 0]) rotate([0, 0, 90]) bend_gap(52.25 + 4 + 3);
      translate([0, case_h, 0]) rotate([0, 0, -90]) bend_gap(case_h - 46.75 - 8 - space);
    }
    rotate([0, -bend * 90, 0]) difference(){
      back_right();
      rotate([0, 0, 90]) bend_gap(46.75 + 8 - 7 - space);
      translate([0, case_h, 0]) rotate([0, 0, -90]) bend_gap(case_h - 46.75 - 8 - space);
    }
    translate([heatsink_l, 0, 0]) rotate([0, bend * 90, 0]) difference(){
      front_right();
      rotate([0, 0, 90]) bend_gap(52.25 + 4 + 3);
    }
  }
}

//projection(cut = false) 
case();