Cleanup macro

.gitignore

@@ -0,0 +1,3 @@
+*.FCStd
+*.FCBak
+*.3mf

pointer.FCMacro

@@ -1,71 +1,60 @@
-# IMU Pointer Enclosure — FreeCAD Macro v5
+# IMU Pointer Enclosure
-# ==========================================
-# Lid drops INSIDE the base.
-# Base has a shelf step cut 1.5mm into the inner walls,
-# LID_STEP mm from the top. Lid rests on that shelf, flush with base top.
-# USB-C notch on front edge of lid keeps port accessible.
-#
-# Layout (top view, front = left):
-#   [USB-C][ XIAO on posts ]<-wires->[ AAA holder ][ grip ]
-# ==========================================
 
 import FreeCAD as App
 import FreeCADGui as Gui
 import Part
-import Mesh
-import os
 from FreeCAD import Base
 
-doc = App.newDocument("IMU_Pointer_v5")
+doc = App.newDocument("pointer")
-
-# ---- PARAMETERS ------------------------------------------------------------
 
+# Global dimensions
 L = 115.0
-W    =  34.0
+W = 36.0
-H    =  28.0
+H = 20.0
-WALL =   2.5
+WALL = 3.5
-CR   =   3.0   # corner fillet radius
+CR = 3.0
+TOL = 0.25
 
-TOL  =   0.25  # fit clearance — lid is this much smaller than the shelf opening
+# Rail and lid
+RAIL_H = 4.5
+RAIL_D = 2.0
+LIP_H = 2.0
+LIP_OVER = 1.5
+LIP_EMBED = 0.2
 
-# Shelf: step cut into inside of base walls near the top
+LID_H = RAIL_H - LIP_H - TOL - 0.55
-# Lid sits on this shelf, flush with the base rim
-SHELF_DEPTH =  1.5   # how far shelf cuts inward from the inner wall face
-SHELF_H     =  2.0   # how tall the shelf step is (from top of base downward)
-                     # lid height = SHELF_H so it sits exactly flush
 
-LID_H = SHELF_H      # lid is exactly as tall as the shelf recess
+# Board dimensions
-
+PCB_T = 1.0
-# XIAO board (front of device)
 BRD_L = 21.0
-BRD_W  = 18.0
+BRD_W = 17.5
-BRD_X  = WALL + 4.0
+BRD_X = WALL
 BRD_Y = (W - BRD_W) / 2
-BRD_Z  = WALL + 4.5
 
-# AAA battery holder
+PLATFORM_H = 0.5
+BRD_Z = WALL + PLATFORM_H
+
+# Clip arms
+ARM_LEN = 5.0
+ARM_THICK = 1.6
+ARM_H = BRD_Z + PCB_T + 0.8
+CLIP_TOL = 0.35
+
+# USB-C cutout
+USBC_W = 11.0
+USBC_H = 7.0
+USBC_Z = 4.5
+
+# Battery section
 BAT_L = 50.0
 BAT_W = 12.0
 BAT_H = 12.0
-BAT_X  = BRD_X + BRD_L + 6.0
+BAT_X = BRD_X + BRD_L + 8.0
 BAT_Y = (W - BAT_W) / 2
+BAT_CLIP_Y = 8.0
 
-# L-post mount
-POST_OD = 3.5
-POST_ID = 1.6
-POST_H  = BRD_Z
-L_ARM   = 2.2
-L_THICK = 1.2
-
-# USB-C cutout on front face
-USBC_W  =  9.5
-USBC_H  =  3.5
-USBC_Z  =  BRD_Z + 0.8
-
-MACRO_DIR = os.path.dirname(os.path.abspath(__file__))
-
-# ---- HELPERS ---------------------------------------------------------------
 
+# Rounded box helper
 def rbox(lx, ly, lz, ox=0, oy=0, oz=0, r=CR):
     b = Part.makeBox(lx, ly, lz, Base.Vector(ox, oy, oz))
     try:
@@ -77,107 +66,209 @@ def rbox(lx, ly, lz, ox=0, oy=0, oz=0, r=CR):
         pass
     return b
 
+
+# Simple box helper
 def box(lx, ly, lz, ox=0, oy=0, oz=0):
     return Part.makeBox(lx, ly, lz, Base.Vector(ox, oy, oz))
 
-def cyl(r, h, ox=0, oy=0, oz=0):
-    return Part.makeCylinder(r, h, Base.Vector(ox, oy, oz))
 
-def export_stl(shape, name):
+# Rounded slot helper
-    path = os.path.join(MACRO_DIR, name)
+def rounded_slot(depth, w, h, ox, oy, oz, r=None):
-    tess = shape.tessellate(0.06)
+    if r is None:
-    m = Mesh.Mesh(list(zip(tess[0], tess[1])))
+        r = h / 2.0
-    m.write(path)
-    print(f"  Saved: {path}")
 
-# ====================================================================
+    r = min(r, h / 2.0, w / 2.0)
-# BASE
-# ====================================================================
 
+    import math
+
+    cy = oy + w / 2.0
+    cz = oz + h / 2.0
+    hw = w / 2.0 - r
+
+    def pt(cx, cy_v, cz_v, angle_deg, radius):
+        a = math.radians(angle_deg)
+        return Base.Vector(
+            cx,
+            cy_v + radius * math.cos(a),
+            cz_v + radius * math.sin(a)
+        )
+
+    l_start = pt(ox, cy - hw, cz, 270, r)
+    l_mid = pt(ox, cy - hw, cz, 180, r)
+    l_end = pt(ox, cy - hw, cz, 90, r)
+    arc_left = Part.Arc(l_start, l_mid, l_end).toShape()
+
+    line_top = Part.makeLine(
+        l_end,
+        pt(ox, cy + hw, cz, 90, r)
+    )
+
+    r_start = pt(ox, cy + hw, cz, 90, r)
+    r_mid = pt(ox, cy + hw, cz, 0, r)
+    r_end = pt(ox, cy + hw, cz, 270, r)
+    arc_right = Part.Arc(r_start, r_mid, r_end).toShape()
+
+    line_bot = Part.makeLine(r_end, l_start)
+
+    wire = Part.Wire([arc_left, line_top, arc_right, line_bot])
+    face = Part.Face(wire)
+
+    return face.extrude(Base.Vector(depth, 0, 0))
+
+
+# Board clip helper
+def make_clip(corner_x, corner_y, inward_x, inward_y):
+
+    plat_w = ARM_THICK + CLIP_TOL
+
+    plat_x = corner_x if inward_x > 0 else corner_x - plat_w
+    plat_y = corner_y if inward_y > 0 else corner_y - plat_w
+
+    platform = box(
+        plat_w, plat_w,
+        PLATFORM_H + PCB_T,
+        plat_x, plat_y, WALL
+    )
+
+    ax_ox = corner_x if inward_x > 0 else corner_x - ARM_LEN
+    ax_oy = corner_y - ARM_THICK - CLIP_TOL if inward_y > 0 else corner_y + CLIP_TOL
+    arm_x = box(ARM_LEN, ARM_THICK, ARM_H, ax_ox, ax_oy, WALL)
+
+    ay_oy = corner_y if inward_y > 0 else corner_y - ARM_LEN
+    ay_ox = corner_x - ARM_THICK - CLIP_TOL if inward_x > 0 else corner_x + CLIP_TOL
+    arm_y = box(ARM_THICK, ARM_LEN, ARM_H, ay_ox, ay_oy, WALL)
+
+    corner_block_w = ARM_THICK + CLIP_TOL
+    cb_ox = corner_x - corner_block_w if inward_x > 0 else corner_x
+    cb_oy = corner_y - corner_block_w if inward_y > 0 else corner_y
+
+    corner_block = box(
+        corner_block_w, corner_block_w, ARM_H,
+        cb_ox, cb_oy, WALL
+    )
+
+    return platform.fuse(arm_x.fuse(arm_y).fuse(corner_block))
+
+
+# Base outer body
 base = rbox(L, W, H)
-# Main inner cavity — full height minus floor
-base = base.cut(box(L - WALL*2, W - WALL*2, H - WALL, WALL, WALL, WALL))
 
-# Shelf recess: widen the top SHELF_H of the inner cavity by SHELF_DEPTH
+# Inner cavity
-# This creates the step the lid rests on
+base = base.cut(
-shelf_cut = box(L - WALL*2 + SHELF_DEPTH*2,
+    box(L - WALL * 2, W - WALL * 2, H - WALL,
-                W - WALL*2 + SHELF_DEPTH*2,
+        WALL, WALL, WALL)
-                SHELF_H + 0.1,
+)
-                WALL - SHELF_DEPTH,
-                WALL - SHELF_DEPTH,
-                H - SHELF_H)
-base = base.cut(shelf_cut)
 
-# USB-C slot on front face (X=0)
+rail_z = H - RAIL_H
-base = base.cut(box(WALL*3, USBC_W, USBC_H,
+groove_h = RAIL_H - LIP_H
-                    -WALL, W/2 - USBC_W/2, USBC_Z))
 
-# ---- L-shaped mounting posts ----
+# Rail grooves
-brd_cx = BRD_X + BRD_L / 2
+base = base.cut(
-brd_cy = BRD_Y + BRD_W / 2
+    box(L - WALL * 2, RAIL_D, groove_h,
-post_corners = [
+        WALL, WALL - RAIL_D, rail_z)
-    (BRD_X + 2.0,         BRD_Y + 2.0),
+)
-    (BRD_X + BRD_L - 2.0, BRD_Y + 2.0),
+
-    (BRD_X + 2.0,         BRD_Y + BRD_W - 2.0),
+base = base.cut(
-    (BRD_X + BRD_L - 2.0, BRD_Y + BRD_W - 2.0),
+    box(L - WALL * 2, RAIL_D, groove_h,
+        WALL, W - WALL, rail_z)
+)
+
+# Lid lips
+lip_z = H - LIP_H
+
+base = base.fuse(
+    box(L - WALL * 2, LIP_OVER, LIP_H,
+        WALL, WALL, lip_z)
+)
+
+base = base.fuse(
+    box(L - WALL * 2, LIP_OVER, LIP_H,
+        WALL, W - WALL - LIP_OVER, lip_z)
+)
+
+# Back slot
+slot_y0 = WALL - RAIL_D
+slot_yw = W - WALL * 2 + RAIL_D * 2
+
+base = base.cut(
+    box(WALL + 1.0, slot_yw, RAIL_H,
+        L - WALL, slot_y0, rail_z)
+)
+
+# Entry bump
+BUMP_H = 0.5
+pad_raw = box(WALL, slot_yw, BUMP_H,
+              L - WALL, slot_y0, rail_z)
+
+pad_trimmed = pad_raw.common(rbox(L, W, H))
+base = base.fuse(pad_trimmed)
+
+# Board clips
+clip_corners = [
+    (BRD_X, BRD_Y, +1, +1),
+    (BRD_X + BRD_L, BRD_Y, -1, +1),
+    (BRD_X, BRD_Y + BRD_W, +1, -1),
+    (BRD_X + BRD_L, BRD_Y + BRD_W, -1, -1),
 ]
-for (px, py) in post_corners:
-    post = cyl(POST_OD/2, POST_H, px, py, WALL)
-    post = post.cut(cyl(POST_ID/2, POST_H + 1.0, px, py, WALL - 0.5))
-    dx = brd_cx - px;  dy = brd_cy - py
-    mag = (dx**2 + dy**2)**0.5;  dx /= mag;  dy /= mag
-    perp_x = -dy;  perp_y = dx;  hw = L_THICK / 2
-    z0 = WALL + POST_H - L_THICK;  z1 = WALL + POST_H
-    p0 = Base.Vector(px - perp_x*hw, py - perp_y*hw, z0)
-    p1 = Base.Vector(px + perp_x*hw, py + perp_y*hw, z0)
-    p2 = Base.Vector(px + perp_x*hw, py + perp_y*hw, z1)
-    p3 = Base.Vector(px - perp_x*hw, py - perp_y*hw, z1)
-    arm = Part.Face(Part.Wire([
-        Part.makeLine(p0,p1), Part.makeLine(p1,p2),
-        Part.makeLine(p2,p3), Part.makeLine(p3,p0)
-    ])).extrude(Base.Vector(dx*L_ARM, dy*L_ARM, 0))
-    base = base.fuse(post.fuse(arm))
 
-# ---- Battery cradle ----
+for cx, cy, ix, iy in clip_corners:
-base = base.cut(box(BAT_L, BAT_W, 3.0, BAT_X, BAT_Y, WALL))
+    base = base.fuse(make_clip(cx, cy, ix, iy))
-base = base.fuse(box(2.0, BAT_W+3.0, BAT_H*0.55, BAT_X-2.0,   BAT_Y-1.5, WALL))
-base = base.fuse(box(2.0, BAT_W+3.0, BAT_H*0.55, BAT_X+BAT_L, BAT_Y-1.5, WALL))
 
-print("[1/2] Base complete.")
+# USB-C opening
-
+base = base.cut(
-# ====================================================================
+    rounded_slot(
-# LID  — sized to drop inside the shelf opening, built at Z=0
+        WALL * 3,
-# ====================================================================
+        USBC_W,
-# Lid outer dimensions match the shelf recess minus tolerance
+        USBC_H,
-LID_L = L - WALL*2 + SHELF_DEPTH*2 - TOL*2
+        -WALL,
-LID_W = W - WALL*2 + SHELF_DEPTH*2 - TOL*2
-
-lid = rbox(LID_L, LID_W, LID_H,
-           WALL - SHELF_DEPTH + TOL,
-           WALL - SHELF_DEPTH + TOL,
-           0, r=1.5)
-
-# USB-C notch on front edge (X=0 face of lid) so port stays accessible
-# The notch is a slot cut from the front edge, aligned with USB-C position
-notch_y = W/2 - USBC_W/2 - (WALL - SHELF_DEPTH + TOL)  # relative to lid origin
-lid = lid.cut(box(WALL*2, USBC_W, USBC_H + 0.5,
-                  -(WALL - SHELF_DEPTH + TOL),   # punch through front face
         W / 2 - USBC_W / 2,
-                  0))
+        USBC_Z
+    )
+)
 
-print("[2/2] Lid complete.")
+# Battery recess
+base = base.cut(
+    box(BAT_L, BAT_W, 3.0,
+        BAT_X, BAT_Y, WALL)
+)
 
-# Export STLs at Z=0 BEFORE any translation
+clip_y_start = BAT_Y + BAT_W / 2 - BAT_CLIP_Y / 2
-print("\nExporting STLs...")
-export_stl(base, "pointer_base.stl")
-export_stl(lid,  "pointer_lid.stl")
 
-# Translate lid up to assembled position for FreeCAD viewport only
+base = base.fuse(
-lid.translate(Base.Vector(0, 0, H - LID_H))
+    box(2.0, BAT_CLIP_Y, BAT_H * 0.55,
+        BAT_X - 2.0, clip_y_start, WALL)
+)
 
-# ====================================================================
+base = base.fuse(
-# DOCUMENT
+    box(2.0, BAT_CLIP_Y, BAT_H * 0.55,
-# ====================================================================
+        BAT_X + BAT_L, clip_y_start, WALL)
+)
+
+# Lid
+TAB_W = RAIL_D - TOL + 0.5
+LID_L = L - WALL * 2 - TOL
+LID_EXTRA_TOL = 0.5
+
+LID_W = (
+    W - WALL * 2
+    - (TOL + LID_EXTRA_TOL) * 2
+    + TAB_W * 2
+)
+
+lid_y0 = WALL + TOL + LID_EXTRA_TOL - TAB_W
+
+lid = box(LID_L, LID_W, LID_H, 0, lid_y0, 0)
+
+lid = lid.cut(
+    box(WALL * 2, USBC_W + TOL, LID_H + 0.2,
+        LID_L - WALL,
+        W / 2 - (USBC_W + TOL) / 2,
+        -0.1)
+)
+
+lid.translate(Base.Vector(WALL + TOL, 0, rail_z))
+
+# Final objects
 base_obj = doc.addObject("Part::Feature", "Pointer_Base")
 base_obj.Shape = base
 base_obj.ViewObject.ShapeColor = (0.12, 0.12, 0.14)
@@ -190,22 +281,3 @@ lid_obj.ViewObject.Transparency = 25
 doc.recompute()
 Gui.activeDocument().activeView().viewIsometric()
 Gui.SendMsgToActiveView("ViewFit")
-
-print()
-print("=" * 62)
-print("IMU Pointer v5 — lid drops INSIDE base")
-print(f"  Outer         : {L:.0f} x {W:.0f} x {H:.0f} mm")
-print(f"  Shelf step    : {SHELF_DEPTH:.1f} mm inward, {SHELF_H:.1f} mm tall")
-print(f"  Lid           : {LID_L:.1f} x {LID_W:.1f} x {LID_H:.1f} mm")
-print(f"  Tolerance     : {TOL:.2f} mm")
-print()
-print("Assembly:")
-print("  Drop lid flat-side-up into the top opening.")
-print("  It rests on the shelf, sitting flush with the base rim.")
-print("  USB-C notch on front edge keeps port fully accessible.")
-print("  To remove: push up from the USB-C hole or pry with fingernail.")
-print()
-print("Print orientation:")
-print("  Base: flat bottom down, no supports")
-print("  Lid : either face down, it's a flat plate — no supports")
-print("=" * 62)