Merge pull request #383 from smkent/ebox

Add new project box features, convert to library

Author: smkent

electronics/project-box/SConscript

@@ -15,9 +15,7 @@ for opts in GenerateOptions(part=["lid", "box"], dims=dimensions):
         model,
         {
             "Part": opts.part,
-            "Width": opts.dims[0],
-            "Length": opts.dims[1],
-            "Height": opts.dims[2],
+            "Dimensions": opts.dims,
         },
     )
 b.Image("demo.png", model, {"Part": "all"})

electronics/project-box/honeycomb-openscad

@@ -0,0 +1 @@
+../../libraries/honeycomb-openscad

electronics/project-box/images/publish/demo.png

@@ -0,0 +1,380 @@
+/*
+ * Electronics project box
+ * By smkent (GitHub) / bulbasaur0 (Printables)
+ *
+ * Licensed under Creative Commons (4.0 International License) Attribution-ShareAlike
+ */
+
+include <honeycomb-openscad/honeycomb.scad>;
+
+/* [Development Toggles] */
+
+module __end_customizer_options__() { }
+
+// Constants //
+
+$fa = $preview ? $fa : 2;
+$fs = $preview ? $fs / 4 : 0.4;
+
+slop = 0.001;
+
+// Functions //
+
+function vec_add(v, add) = [for (i = v) i + add];
+
+function _eyelet_thickness() = $e_thickness * 2;
+
+function _mounting_screw_xpos() = $e_thickness + $e_mounting_screw_diameter * 1.125;
+
+function _mounting_screw_eyelet_d() = $e_mounting_screw_diameter * 1.125;
+
+// Public Modules //
+
+module ebox(
+    dimensions,
+    thickness=2.4,
+    lid_height=3.9,
+    screw_diameter=3,
+    insert_diameter=4.5,
+    insert_depth=10,
+    screw_style="flag",
+    mounting_screws=true,
+    mounting_screw_diameter=4,
+    mounting_screw_style="flat",
+    pattern_lid=0,
+    pattern_bottom=0,
+    pattern_walls=[0, 0, 0, 0]
+) {
+    $e_dimensions = dimensions;
+    $e_width = dimensions[0];
+    $e_length = dimensions[1];
+    $e_height = dimensions[2];
+    $e_thickness = thickness;
+    $e_lid_height = lid_height;
+    $e_screw_diameter = screw_diameter;
+    $e_insert_diameter = insert_diameter;
+    $e_insert_depth = insert_depth;
+    $e_screw_style = screw_style;
+    $e_mounting_screws = mounting_screws;
+    $e_mounting_screw_diameter = mounting_screw_diameter;
+    $e_mounting_screw_style = mounting_screw_style;
+    $e_pattern_lid = pattern_lid;
+    $e_pattern_bottom = pattern_bottom;
+    $e_pattern_walls = pattern_walls;
+    ebox_adjustments()
+    children();
+}
+
+module ebox_adjustments(
+    print_orientation=true,
+    screw_inset=4,
+    corner_radius=3,
+    edge_radius=1.5,
+    screw_count=4,
+    screw_fit=0.4
+) {
+    $e_print_orientation = print_orientation;
+    $e_screw_inset = screw_inset;
+    $e_corner_radius = corner_radius;
+    $e_edge_radius = edge_radius;
+    $e_screw_count = screw_count;
+    $e_screw_fit = screw_fit;
+    children();
+}
+
+module ebox_part(part) {
+    if (Part == "preview") {
+        _box();
+        translate([0, 0, slop])
+        _lid();
+    } else if (Part == "all") {
+        sep = $e_length / 2 + $e_thickness * 2;
+        translate([0, sep, 0])
+        _box();
+        translate([0, -sep, 0])
+        if ($e_print_orientation) {
+            rotate([180, 0, 0])
+            translate([0, 0, -($e_height + $e_thickness * 2)])
+            _lid();
+        } else {
+            translate([0, 0, -($e_height - $e_lid_height) - $e_thickness * 2])
+            _lid();
+        }
+    } else if (Part == "box") {
+        _box();
+    } else if (Part == "lid") {
+        if ($e_print_orientation) {
+            rotate([180, 0, 0])
+            translate([0, 0, -($e_height + $e_thickness * 2)])
+            _lid();
+        } else {
+            translate([0, 0, -($e_height + $e_thickness)])
+            _lid();
+        }
+    }
+}
+
+module ebox_cutouts() {
+}
+
+module ebox_interior() {
+}
+
+module ebox_extras() {
+}
+
+// Internal Modules //
+
+module _hc_pattern(x, y, hex_size=8, separation=2.2, height=$e_thickness) {
+    translate([0, 0, -slop * 5])
+    linear_extrude(height=height + slop * 10)
+    difference() {
+        square([x, y], center=true);
+        translate([-x/2, -y/2])
+        honeycomb(x, y, hex_size, separation, whole_only=true);
+    }
+}
+
+module _hull_pair(height) {
+    slop = 0.001;
+    hull() {
+        for (child_obj = [
+            // Child index, height offset
+            [0, 0],
+            [1, height - slop]
+        ]) {
+            translate([0, 0, child_obj[1]])
+            linear_extrude(height=slop)
+            children(child_obj[0]);
+        }
+    }
+}
+
+module _round_3d(radius = $e_edge_radius) {
+    if (radius == 0) {
+        children();
+    } else {
+        render()
+        minkowski() {
+            children();
+            for (mz = [0, 1])
+            mirror([0, 0, mz])
+            cylinder(r1=radius, r2=0, h=radius);
+        }
+    }
+}
+
+module _screw_hole(d, h, fit=0, style="flat", print_upside_down=false) {
+    inset_min_h = (style == "inset") ? max((h - d), 2) - (h - d) : 0;
+    translate([0, 0, -slop])
+    cylinder(d=(d + fit), h=h + slop * 2);
+    if (style == "countersink" || style == "inset") {
+        translate([0, 0, h + inset_min_h + slop * 2])
+        mirror([0, 0, 1])
+        cylinder(d1=d * 2, d2=d * (style == "inset" ? 2 : 1), h=d);
+    }
+    if (style == "inset" && print_upside_down) {
+        layer_height = 0.2;
+        translate([0, 0, (h + inset_min_h) - d - layer_height])
+        linear_extrude(height=layer_height + slop * 2)
+        intersection() {
+            square([d * 2, d + fit], center=true);
+            circle(d=d*2);
+        }
+    }
+}
+
+module _at_screws() {
+    if ($e_screw_count == 2) {
+        for (m = [0, 1])
+        mirror([m, 0])
+        mirror([0, m])
+        translate([$e_width / 2 - $e_screw_inset, $e_length / 2 - $e_screw_inset])
+        children();
+    } else {
+        for (mx = [0, 1], my = [0, 1])
+        mirror([mx, 0])
+        mirror([0, my])
+        translate([$e_width / 2 - $e_screw_inset, $e_length / 2 - $e_screw_inset])
+        children();
+    }
+}
+
+module _at_box_screws() {
+    for (mx = [0, 1])
+    mirror([mx, 0])
+    translate([$e_width / 2 + _mounting_screw_xpos(), 0])
+    children();
+}
+
+module _box_shape(radius=$e_corner_radius, add=0) {
+    offset(r=radius)
+    offset(r=-radius)
+    square([$e_width + add * 2, $e_length + add * 2], center=true);
+}
+
+module _box_interior_base() {
+    union() {
+        screw_corner = $e_insert_diameter + $e_screw_inset;
+        start_ht = $e_height - $e_lid_height + $e_insert_diameter * 0.40;
+        interior_corner_radius = max(0.5, ($e_corner_radius - $e_thickness));
+
+        // Interior shape
+        color("mintcream", 0.8)
+        translate([0, 0, $e_thickness])
+        _round_3d()
+        translate([0, 0, $e_edge_radius])
+        union() {
+            linear_extrude(height=(start_ht - $e_insert_depth - screw_corner) - $e_edge_radius * 2)
+            _box_shape(add=-$e_edge_radius);
+
+            linear_extrude(height=$e_height - $e_edge_radius * 2)
+            offset(r=interior_corner_radius)
+            offset(r=-interior_corner_radius)
+            difference() {
+                _box_shape(add=-$e_edge_radius);
+                _at_screws()
+                union() {
+                    r = $e_insert_diameter + $e_edge_radius;
+                    circle(r=r);
+                    for (tr = [[0, -r], [-r, 0]])
+                    translate(tr)
+                    square([r, r]);
+                }
+            }
+        }
+
+        // Interior screw support chamfer
+        color("mediumpurple", 0.8)
+        translate([0, 0, (start_ht - $e_insert_depth - screw_corner) + $e_thickness])
+        union() {
+            _hull_pair(screw_corner) {
+                offset(r=interior_corner_radius)
+                offset(r=-interior_corner_radius)
+                _box_shape(radius=$e_corner_radius + $e_edge_radius);
+                _box_shape(radius=$e_corner_radius + $e_edge_radius, add=-screw_corner);
+            }
+            if ($e_edge_radius > 0) {
+                translate([0, 0, -$e_edge_radius + slop])
+                linear_extrude(height=$e_edge_radius + slop)
+                _box_shape(radius=$e_corner_radius + $e_edge_radius);
+            }
+        }
+    }
+}
+
+module _box_body() {
+    translate([0, 0, $e_edge_radius])
+    _round_3d()
+    linear_extrude(height=$e_height + $e_thickness * 2 - $e_edge_radius * 2)
+    _box_shape(add=$e_thickness - $e_edge_radius);
+}
+
+module _box_screw_eyelets() {
+    eyelet_round = _mounting_screw_xpos() * 2;
+    _round_3d()
+    translate([0, 0, $e_edge_radius])
+    linear_extrude(height=_eyelet_thickness() - $e_edge_radius * 2)
+    offset(r=-$e_edge_radius)
+    offset(r=$e_thickness)
+    offset(r=-eyelet_round)
+    offset(r=eyelet_round)
+    union() {
+        _box_shape();
+        _at_box_screws()
+        union() {
+            d = _mounting_screw_eyelet_d();
+            circle(d=d * 2);
+            translate([-d, 0])
+            square(d * 2, center=true);
+        }
+    }
+}
+
+module _box_screws() {
+    _at_box_screws()
+    _screw_hole(
+        d=$e_mounting_screw_diameter,
+        fit=$e_screw_fit,
+        h=_eyelet_thickness() + slop * 2,
+        style=$e_mounting_screw_style
+    );
+}
+
+module _box_patterns() {
+    if ($e_pattern_bottom)
+    _hc_pattern($e_width - $e_screw_inset * 2, $e_length - $e_screw_inset * 2);
+    for (fw = [0:1:3]) {
+        if ($e_pattern_walls[fw] > 0) {
+            pattern_x = (((fw % 2) == 0) ? $e_width : $e_length) - $e_insert_diameter * 2 * 2;
+            pos_y = ((fw % 2) == 0) ? $e_length : $e_width;
+            mirror([fw == 3 ? 1 : 0, fw == 2 ? 1 : 0])
+            rotate((fw % 2) != 0 ? 90 : 0)
+            translate([0, pos_y / 2 + $e_thickness, ($e_height - $e_lid_height) / 2 + $e_thickness])
+            rotate([90, 0, 0])
+            _hc_pattern(pattern_x - $e_screw_inset * 2, ($e_height - $e_lid_height) - $e_screw_inset * 2);
+        }
+    }
+}
+
+module _box_interior() {
+    difference() {
+        _box_interior_base();
+        ebox_interior();
+    }
+}
+
+module _box() {
+    color("mintcream", 0.8)
+    render()
+    union() {
+        difference() {
+            intersection() {
+                union() {
+                    if ($e_mounting_screws)
+                    _box_screw_eyelets();
+                    _box_body();
+                }
+                linear_extrude(height=$e_height + $e_thickness * 2 - $e_lid_height)
+                scale([2, 1])
+                _box_shape(add=$e_thickness + $e_edge_radius, radius=0);
+            }
+            _box_interior();
+            _at_screws()
+            translate([0, 0, ($e_height + $e_thickness) - $e_lid_height - $e_insert_depth])
+            _screw_hole(d=$e_insert_diameter, fit=$e_screw_fit, h=$e_insert_depth + $e_thickness);
+            if ($e_mounting_screws)
+            _box_screws();
+            _box_patterns();
+            ebox_cutouts();
+        }
+    }
+    ebox_extras();
+}
+
+module _lid() {
+    color("lightsteelblue", (Part == "preview" ? 0.4 : 0.8))
+    render()
+    difference() {
+        intersection() {
+            _box_body();
+            translate([0, 0, $e_height + $e_thickness * 2 - $e_lid_height])
+            linear_extrude(height=$e_lid_height)
+            _box_shape(add=$e_thickness + $e_edge_radius, radius=0);
+        }
+        _box_interior();
+        _at_screws()
+        translate([0, 0, $e_height + $e_thickness * 2 - $e_lid_height])
+        _screw_hole(
+            d=$e_screw_diameter,
+            fit=$e_screw_fit,
+            h=$e_lid_height,
+            style=$e_screw_style,
+            print_upside_down=true
+        );
+        if ($e_pattern_lid)
+        translate([0, 0, $e_height + $e_thickness])
+        _hc_pattern($e_width - $e_screw_inset * 2, $e_length - $e_screw_inset * 2);
+        ebox_cutouts();
+    }
+}