Create esp-pcb-40mm

electronics/esp-pcb-40mm/LICENSE

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+This work is licensed under the Creative Commons Attribution-ShareAlike 4.0 International License. To view a copy of this license, visit http://creativecommons.org/licenses/by-sa/4.0/ or send a letter to Creative Commons, PO Box 1866, Mountain View, CA 94042, USA.

electronics/esp-pcb-40mm/README.md

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+# ESPHome 40x40mm PCB mount
+
+![This model is a work in progress][work-in-progress-badge]
+[![CC-BY-SA-4.0 license][license-badge]][license]
+
+PCB mount for custom 40x40mm ESPHome PCB designs
+
+![Model render](images/readme/demo.png)
+
+## License
+
+This model is licensed under [Creative Commons (4.0 International License) Attribution-ShareAlike][license].
+
+
+[license]: http://creativecommons.org/licenses/by-sa/4.0/
+[license-badge]: /_static/license-badge-cc-by-sa-4.0.svg
+[work-in-progress-badge]: /_static/work-in-progress-badge.svg

electronics/esp-pcb-40mm/SConscript

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+Import("env")
+b = ModelBuilder(env)
+
+model = "esp-pcb-40mm.scad"
+
+for opts in GenerateOptions(
+    x=[1, 2, 3], y=[1, 2, 3], screw_x=[(0, ""), (1, "-xscrew")], height=[6, 10]
+):
+    b.STL(
+        f"esp-pcb-40mm-{opts.x}x{opts.y}-{opts.height}mm{opts.screw_x_fn}.stl",
+        model,
+        {
+            "PCB_X": opts.x,
+            "PCB_Y": opts.y,
+            "Height": opts.height,
+            "Mounting_Screw_Holes_X": opts.screw_x,
+        },
+    )
+
+b.Image("demo.png", model, {"Mounting_Screw_Holes_X": 1})
+
+b.add_default_targets()
+
+# vim: ft=python

electronics/esp-pcb-40mm/esp-pcb-40mm.scad

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+/*
+ * ESPHome 40x40mm PCB mount
+ * By smkent (GitHub) / bulbasaur0 (Printables)
+ *
+ * Licensed under Creative Commons (4.0 International License) Attribution-ShareAlike
+ */
+
+/* [Rendering Options] */
+Preview_PCB = true;
+// Print_Orientation = true;
+
+/* [PCB] */
+// 40mm units
+PCB_X = 1; // [1:1:3]
+
+// 40mm units
+PCB_Y = 1; // [1:1:3]
+
+/* [Size] */
+Height = 6; // [5:0.5:20]
+Thickness = 2.0; // [1:0.1:5]
+Edge_Radius = 0.5; // [0:0.5:1]
+Screw_Insert_Diameter = 4.5; // [3:0.1:6]
+
+/* [Features] */
+Mounting_Screw_Holes_X = false;
+Mounting_Screw_Holes_Y = false;
+Mounting_Screw_Hole_Chamfer = false;
+Mounting_Screw_Diameter = 4.5;
+PCB_Support_Chamfer = 1.5; // [0:0.1:3]
+
+/* [Advanced Options] */
+Inner_Holes = true;
+
+module __end_customizer_options__() { }
+
+// Constants //
+
+$fa = $preview ? $fa : 2;
+$fs = $preview ? $fs : 0.4;
+
+pcb_grid = 40;
+pcb_grid_sep = 2;
+corner_radius = 3;
+hole_inset = 3;
+pcb_hole_d = 3.2;
+pcb_thick = 1.6;
+
+hole_d = Screw_Insert_Diameter;
+edge_outset = 2;
+hole_to_edge = edge_outset + hole_inset;
+pcb_hole_clearance = 2.495 + 0.5;
+edge_radius = Edge_Radius;
+
+slop = 0.001;
+
+// Functions //
+
+pcb_x = PCB_X * pcb_grid + (PCB_X - 1) * pcb_grid_sep;
+pcb_y = PCB_Y * pcb_grid + (PCB_Y - 1) * pcb_grid_sep;
+
+// Modules //
+
+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 = 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 at_pcb_grid() {
+    translate([
+        -(PCB_X - 1) / 2 * (pcb_grid_sep + pcb_grid),
+        -(PCB_Y - 1) / 2 * (pcb_grid_sep + pcb_grid),
+    ])
+    for (px = [0:1:PCB_X - 1], py = [0:1:PCB_Y - 1])
+    translate([px * (pcb_grid + pcb_grid_sep), py * (pcb_grid + pcb_grid_sep)])
+    union() {
+        $grid_x = px;
+        $grid_y = py;
+        children();
+    }
+}
+
+module at_pcb_holes() {
+    at_pcb_grid()
+    union() {
+        px = $grid_x;
+        py = $grid_y;
+        for (hx = [0, 1], hy = [0, 1]) {
+            edge_x0 = (px == 0 && hx == 0);
+            edge_x1 = (px == (PCB_X - 1) && hx == 1);
+            edge_y0 = (py == 0 && hy == 0);
+            edge_y1 = (py == (PCB_Y - 1) && hy == 1);
+            inner_x = !(edge_x0 || edge_x1);
+            inner_y = !(edge_y0 || edge_y1);
+            inner = (inner_x && inner_y);
+            if (!inner || (Inner_Holes && inner))
+            mirror([1 - hx, 0])
+            mirror([0, 1 - hy])
+            translate([pcb_grid / 2 - hole_inset, pcb_grid / 2 - hole_inset])
+            children();
+        }
+    }
+}
+
+module at_pcb_grid_corners() {
+    translate([
+        -PCB_X / 2 * (pcb_grid + pcb_grid_sep),
+        -PCB_Y / 2 * (pcb_grid + pcb_grid_sep)
+    ])
+    for (px = [0:1:PCB_X], py = [0:1:PCB_Y]) {
+        inner = (px > 0 && px < PCB_X) && (py > 0 && py < PCB_Y);
+        if (!inner || (Inner_Holes && inner))
+        translate([
+            px * (pcb_grid + pcb_grid_sep),
+            py * (pcb_grid + pcb_grid_sep)
+        ])
+        children();
+    }
+}
+
+module at_base_mount_screws(enable_x=true, enable_y=true) {
+    screw_offset = Mounting_Screw_Diameter + (pcb_grid + pcb_grid_sep) / 2;
+    at_pcb_grid() {
+        if (enable_x && Mounting_Screw_Holes_X) {
+            if ($grid_x == 0)
+            translate([-screw_offset, 0])
+            children();
+            if ($grid_x == PCB_X - 1)
+            translate([screw_offset, 0])
+            children();
+        }
+        if (enable_y && Mounting_Screw_Holes_Y) {
+            if ($grid_y == 0)
+            translate([0, -screw_offset])
+            children();
+            if ($grid_y == PCB_Y - 1)
+            translate([0, screw_offset])
+            children();
+        }
+    }
+}
+
+module pcb() {
+    color("darkseagreen", 0.5)
+    linear_extrude(height=pcb_thick)
+    difference() {
+        $fs = $preview ? ($fs / 4) : $fs;
+        offset(r=corner_radius)
+        offset(r=-corner_radius)
+        square([pcb_x, pcb_y], center=true);
+        at_pcb_holes()
+        circle(d=pcb_hole_d);
+    }
+}
+
+module base_shape() {
+    offset(r=-edge_radius)
+    offset(r=hole_to_edge)
+    offset(r=-hole_to_edge)
+    square([pcb_x + edge_outset * 2, pcb_y + edge_outset * 2], center=true);
+}
+
+module base_cutouts() {
+    at_pcb_grid()
+    offset(r=-edge_radius)
+    offset(r=hole_to_edge * 1.25)
+    offset(r=-hole_to_edge * 1.25)
+    square(pcb_grid - (hole_to_edge * 2), center=true);
+}
+
+module base_support_quad_shape() {
+    offset(r=3)
+    offset(r=-3)
+    square((hole_inset + pcb_hole_clearance) * 2 + pcb_grid_sep, center=true);
+}
+
+module base_supports() {
+    intersection() {
+        linear_extrude(height=Height * 2)
+        base_shape();
+        translate([0, 0, edge_radius])
+        // linear_extrude(height=Height - edge_radius * 2)
+        at_pcb_grid_corners()
+        hull_pair(Height - edge_radius * 2) {
+            offset(r=PCB_Support_Chamfer)
+            base_support_quad_shape();
+            base_support_quad_shape();
+        }
+    }
+}
+
+module base_mount_edges() {
+    offset(r=-hole_to_edge)
+    offset(r=hole_to_edge)
+    union() {
+        base_shape();
+        for (enable_x = [0, 1])
+        hull() {
+            offset(r=(-hole_to_edge - hole_inset))
+            base_shape();
+            at_base_mount_screws(enable_x=enable_x, enable_y=!enable_x)
+            circle(d=Mounting_Screw_Diameter * (Mounting_Screw_Hole_Chamfer ? 3 : 2.25));
+        }
+    }
+}
+
+module base_body() {
+    base_supports();
+
+    translate([0, 0, edge_radius])
+    linear_extrude(height=Thickness - edge_radius * 2)
+    difference() {
+        union() {
+            base_shape();
+            base_mount_edges();
+        }
+        base_cutouts();
+    }
+}
+
+module base_holes() {
+    at_pcb_holes() {
+        translate([0, 0, -slop])
+        cylinder(d=hole_d, h=Height + slop * 2);
+        translate([0, 0, Height - edge_radius])
+        cylinder(d1=hole_d, d2=hole_d + 2 * edge_radius, h=edge_radius + slop);
+        translate([0, 0, -slop])
+        cylinder(d1=hole_d + 2 * edge_radius, d2=hole_d, h=edge_radius + slop);
+    }
+    at_base_mount_screws() {
+        // translate([0, 0, -slop])
+        translate([0, 0, Thickness])
+        mirror([0, 0, 1]) {
+            cylinder(d=Mounting_Screw_Diameter, h=Height + Mounting_Screw_Diameter + slop * 2);
+            if (Mounting_Screw_Hole_Chamfer)
+            cylinder(d1=Mounting_Screw_Diameter*2, d2=Mounting_Screw_Diameter, h=Mounting_Screw_Diameter / 2);
+        }
+    }
+}
+
+module base() {
+    color("mintcream", 0.9)
+    render()
+    difference() {
+        round_3d()
+        base_body();
+        base_holes();
+    }
+}
+
+module main() {
+    base();
+    if ($preview && Preview_PCB)
+    translate([0, 0, Height + slop])
+    pcb();
+}
+
+main();