Better clip-in top mechanism
This commit is contained in:
@@ -1,37 +1,35 @@
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"""
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IMU Pointer Enclosure — v6
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IMU Pointer Enclosure — v8
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============================
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Fixes from v5 (diagnosed from rendered images):
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Changes from v7:
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1. BOTTOM HOLE:
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v5 built the bottom shell from a full-height box (0→H) then trimmed
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at SPLIT_Z. The taper wedge interacted badly with the split cut near
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X=0 leaving a hole in the floor. Fix: build bottom outer solid only
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to SPLIT_Z height — no trimming step needed, no interaction.
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1. SNAP-LOCK JOINT:
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Removed the flex notches that were cutting through the tongue (they were
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weakening it without providing any positive lock). Replaced with a snap
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ridge system: a small rectangular bump is added to the OUTER face of the
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tongue on each long side at mid-tongue height. The top-shell groove gets a
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matching recess (undercut) so the ridge clicks in when the top is pushed
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down. To release, flex the shell sides slightly outward.
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2. TOP SHELL WALLS PROTRUDING BELOW SPLIT:
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v5 top_outer started at SPLIT_Z but the cavity inside started at
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SPLIT_Z + WALL, leaving WALL=3.5mm of solid wall below the groove —
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visually protruding past the bottom shell. Fix: the top shell outer
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solid starts at SPLIT_Z. The groove is cut starting exactly at SPLIT_Z
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so there is zero protrusion below the split line.
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2. LARGER BUTTON APERTURE:
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BTN_HOLE_R increased from 8 mm → 10 mm (⌀20 mm contact face).
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Cap shaft/rim scale accordingly. Makes it much harder to miss the button.
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3. BUTTON CAP NOT FLUSH / SITTING PROUD:
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Aperture cylinder had arithmetic-derived Z that could miss the top wall
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faces after filleting. Fix: aperture runs from Z=SPLIT_Z (well inside
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the cavity) all the way to Z=H+2 — brute-force punch, impossible to miss.
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4. CAP RIM SITS UNDER OUTER FACE (not above it):
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Cap is placed so shaft top = H (flush). Rim hangs BELOW the top face
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inside the cavity — correct retention geometry. The cap shaft top is
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exactly flush with H. No part of the cap protrudes above H.
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3. FOUR SCREW POSTS FOR BUTTON DAUGHTERBOARD:
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Previous design had 2 posts only in Y. Replaced with 4 posts in a 2×2
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grid centred under the button. Pin pitch 2 mm c-to-c → posts at
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(BTN_X ± 1 mm, BTN_CY ± 1 mm). Screw hole ⌀0.9 mm (just under 1 mm),
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post OD 4 mm for adequate wall thickness around the hole.
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Split joint design:
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- Bottom shell has a TONGUE that projects UP from SPLIT_Z.
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The tongue is a thin rectangular frame (inner perimeter of the walls).
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- Top shell has a matching GROOVE cut into the inside of its lower edge,
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starting exactly at SPLIT_Z (the bottom face of the top shell).
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- Two flex notches cut through the tongue on the long sides allow snap fit.
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- Bottom shell TONGUE projects UP from SPLIT_Z (thin rectangular frame).
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- SNAP RIDGE: small box bump on the outer long-side faces of the tongue,
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at ~mid tongue height. Ridge stands proud of the tongue outer face by
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RIDGE_PROUD (0.4 mm), so the groove wall deflects it inward during
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insertion and snaps into RIDGE_RECESS cut into the groove wall.
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- Top shell GROOVE cut into the inside of its lower edge.
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- RIDGE RECESS: matching pocket cut into the outer face of the groove to
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receive the snap ridge.
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"""
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import FreeCAD as App
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@@ -40,7 +38,7 @@ import Part
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import math
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from FreeCAD import Base
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doc = App.newDocument("pointer_v7")
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doc = App.newDocument("pointer_v8")
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# ─────────────────────────────────────────────────────────────────────────────
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# DIMENSIONS
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@@ -48,13 +46,12 @@ doc = App.newDocument("pointer_v7")
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L = 115.0 # length (X): front=0, back=L
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W = 36.0 # width (Y)
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H = 22.0 # height (Z): bottom=0, top=H
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WALL = 4.5 # wall thickness (+1 mm vs v6 — closes taper floor gap)
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WALL = 4.5 # wall thickness
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CR = 5.0 # corner fillet radius (vertical edges)
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TOL = 0.25 # fit tolerance
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# Taper: front of bottom shell is TAPER_RISE mm shorter than back.
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# Applied only to the BOTTOM shell (it's where the ergonomic taper lives).
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TAPER_RISE = 0.0 # no taper — removed per user request
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# Taper: removed per user request
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TAPER_RISE = 0.0
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TAPER_LEN = 100.0 # unused but kept to avoid NameError
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# Split plane
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@@ -69,9 +66,13 @@ TONGUE_T = 1.2 # tongue wall thickness
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GROOVE_H = TONGUE_H + TOL
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GROOVE_T = TONGUE_T + TOL
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# Flex notch through tongue (for snap release)
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NOTCH_W = 8.0
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NOTCH_H = TONGUE_H + 0.5
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# Snap ridge on tongue long sides
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# Ridge sits on the OUTER face of the tongue (the face against the groove wall)
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# at mid-tongue height. The groove wall has a matching recess.
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RIDGE_W = 12.0 # length of ridge along X (centred on enclosure)
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RIDGE_H = 0.8 # height of the ridge bump
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RIDGE_PROUD = 0.4 # how far ridge protrudes beyond tongue outer face
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RIDGE_Z_OFF = (TONGUE_H - RIDGE_H) / 2.0 # centres ridge vertically in tongue
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# ─────────────────────────────────────────────────────────────────────────────
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# IMU BOARD
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@@ -99,16 +100,16 @@ BAT_Y = (W - BAT_W) / 2.0
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BAT_CLIP_Y = 8.0
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# ─────────────────────────────────────────────────────────────────────────────
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# BUTTON
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# BUTTON — enlarged aperture for easier contact
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# ─────────────────────────────────────────────────────────────────────────────
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BTN_X = 28.0
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BTN_CY = W / 2.0
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BTN_HOLE_R = 8.0
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CAP_SHAFT_R = BTN_HOLE_R - 0.4 # 0.4 mm radial clearance in hole
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CAP_SHAFT_H = WALL # shaft fills top wall → top face flush
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CAP_RIM_R = BTN_HOLE_R + 2.0 # 2 mm wider than hole → retention
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BTN_HOLE_R = 10.0 # ⌀20 mm — up from ⌀16 mm for easier press
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CAP_SHAFT_R = BTN_HOLE_R - 0.4 # 0.4 mm radial clearance
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CAP_SHAFT_H = WALL # shaft fills top wall → top face flush
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CAP_RIM_R = BTN_HOLE_R + 2.0 # 2 mm wider than hole → retention
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CAP_RIM_H = 1.5
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NUBBIN_R = 1.8
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NUBBIN_R = 2.2 # slightly larger nubbin to match bigger cap
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NUBBIN_H = 2.0
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# Switch geometry (adjust to match your Omron)
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@@ -126,9 +127,14 @@ if PCB_BOT_Z < floor_top_shell + 0.5:
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PCB_TOP_Z = PCB_BOT_Z + PCB_T
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POST_H = PCB_BOT_Z - floor_top_shell
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POST_OD = 4.0; POST_R = POST_OD / 2.0
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POST_ID = 1.9; POST_IR = POST_ID / 2.0
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POST_SEP = 3.0
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# ── Screw posts ──────────────────────────────────────────────────────────────
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# 4 posts in a 2×2 grid centred under the button.
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# Pin pitch 2 mm c-to-c → offsets ±1 mm in both X and Y from button centre.
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POST_OD = 4.0; POST_R = POST_OD / 2.0
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POST_ID = 0.9; POST_IR = POST_ID / 2.0 # just under ⌀1 mm
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POST_PITCH = 2.0 # 2 mm centre-to-centre
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POST_OFFS = POST_PITCH / 2.0 # ±1 mm from centre
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BPCB_L = 16.0
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BPCB_W = 16.0
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@@ -204,10 +210,8 @@ def make_clip(cx, cy, ix, iy):
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bot_outer = box(L, W, SPLIT_Z)
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bot_outer = fillet_vert(bot_outer, CR, min_len=SPLIT_Z * 0.4)
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# Fillet the long horizontal edges the user holds.
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# These are the 4 edges running in X at Z≈0 and Z≈SPLIT_Z, on both long sides.
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# Same fillet applied to equivalent edges on the top shell later.
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EDGE_FILLET = 2.5 # mm — soft and comfortable, visible but not decorative
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# Fillet the bottom long horizontal edges (comfort grip)
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EDGE_FILLET = 2.5
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try:
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h_edges = []
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for e in bot_outer.Edges:
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@@ -217,8 +221,6 @@ try:
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dx = abs(v0.X - v1.X)
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dz = abs(v0.Z - v1.Z)
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dy = abs(v0.Y - v1.Y)
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# Long edge in X, horizontal, on a long side face —
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# but ONLY at Z≈0 (bottom face). Exclude Z≈SPLIT_Z (the join edge).
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z_mid = (v0.Z + v1.Z) / 2.0
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if dx > L * 0.5 and dz < 0.5 and dy < 0.5 and z_mid < 1.0:
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h_edges.append(e)
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@@ -230,33 +232,47 @@ try:
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except Exception as exc:
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print(f"Bottom shell horizontal fillet skipped: {exc}")
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# No taper wedge — removed per user request
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# 3. Inner cavity — floor at WALL, ceiling at SPLIT_Z (open top, no ceiling)
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# 3. Inner cavity
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bot_cav_lx = L - WALL * 2
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bot_cav_ly = W - WALL * 2
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bot_cav_lz = SPLIT_Z - WALL # floor(WALL) → SPLIT_Z
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bot_cav_lz = SPLIT_Z - WALL
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bot_inner = box(bot_cav_lx, bot_cav_ly, bot_cav_lz, WALL, WALL, WALL)
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bot_shell = bot_outer.cut(bot_inner)
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# 4. Tongue (projects UP from SPLIT_Z, inner perimeter frame)
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# Outer edge of tongue = inner face of outer wall = WALL from outside
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# Inner edge of tongue = WALL + TONGUE_T from outside
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t_slab = box(bot_cav_lx, bot_cav_ly, TONGUE_H,
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WALL, WALL, SPLIT_Z)
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t_cut = box(bot_cav_lx - TONGUE_T*2, bot_cav_ly - TONGUE_T*2, TONGUE_H + 1,
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WALL + TONGUE_T, WALL + TONGUE_T, SPLIT_Z - 0.5)
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tongue = t_slab.cut(t_cut)
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# Flex notches on the two long sides (parallel to X)
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nx0 = L / 2.0 - NOTCH_W / 2.0
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for ny_start in [WALL, W - WALL - TONGUE_T]:
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tongue = tongue.cut(
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box(NOTCH_W, TONGUE_T + 0.5, NOTCH_H,
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nx0, ny_start - 0.1, SPLIT_Z - 0.1))
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# 5. Snap ridges on the tongue outer long-side faces
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# The tongue outer face sits at Y=WALL and Y=W-WALL (bottom shell outer wall
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# inner face). We add a small proud bump to each long side (the Y faces).
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#
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# Long sides run in X. The tongue outer face in -Y direction is at Y=WALL,
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# outer face in +Y direction is at Y=W-WALL.
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#
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# Ridge box for -Y side:
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# X: centred on L/2, width RIDGE_W
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# Y: from (WALL - RIDGE_PROUD) to WALL (proud outward = -Y direction)
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# Z: from (SPLIT_Z + RIDGE_Z_OFF) height RIDGE_H
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#
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# Ridge box for +Y side:
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# Y: from (W - WALL) to (W - WALL + RIDGE_PROUD)
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#
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ridge_x0 = L / 2.0 - RIDGE_W / 2.0
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ridge_z0 = SPLIT_Z + RIDGE_Z_OFF
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ridge_neg_y = box(RIDGE_W, RIDGE_PROUD, RIDGE_H,
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ridge_x0, WALL - RIDGE_PROUD, ridge_z0)
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ridge_pos_y = box(RIDGE_W, RIDGE_PROUD, RIDGE_H,
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ridge_x0, W - WALL, ridge_z0)
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tongue = tongue.fuse(ridge_neg_y).fuse(ridge_pos_y)
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bot_shell = bot_shell.fuse(tongue)
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# 5. IMU clips
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# 6. IMU clips
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for cx, cy, ix, iy in [
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(BRD_X, BRD_Y, +1, +1),
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(BRD_X + BRD_L, BRD_Y, -1, +1),
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@@ -265,15 +281,14 @@ for cx, cy, ix, iy in [
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]:
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bot_shell = bot_shell.fuse(make_clip(cx, cy, ix, iy))
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# 6. USB-C slot — starts at X = -WALL*3 so it punches through the rounded
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# front face cleanly regardless of fillet radius
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# 7. USB-C slot
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bot_shell = bot_shell.cut(
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rounded_slot(WALL * 6, USBC_W, USBC_H,
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-WALL * 3,
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W / 2.0 - USBC_W / 2.0,
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USBC_Z))
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# 7. Battery bay
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# 8. Battery bay
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bot_shell = bot_shell.cut(box(BAT_L, BAT_W, 3.0, BAT_X, BAT_Y, WALL))
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cy0 = BAT_Y + BAT_W / 2.0 - BAT_CLIP_Y / 2.0
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bot_shell = bot_shell.fuse(box(2.0, BAT_CLIP_Y, BAT_H * 0.55, BAT_X - 2.0, cy0, WALL))
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@@ -288,8 +303,7 @@ top_h = H - SPLIT_Z # = 7.5 mm
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top_outer = box(L, W, top_h, 0, 0, SPLIT_Z)
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top_outer = fillet_vert(top_outer, CR, min_len=top_h * 0.4)
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# Fillet the long horizontal edges of the top shell —
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# the top edges (Z≈H) are the ones selected in blue in the user's screenshot.
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# Fillet the top long horizontal edges
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try:
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th_edges = []
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for e in top_outer.Edges:
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@@ -299,8 +313,6 @@ try:
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dx = abs(v0.X - v1.X)
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dz = abs(v0.Z - v1.Z)
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dy = abs(v0.Y - v1.Y)
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# Long edge in X, horizontal, on a long side face —
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# ONLY at Z≈H (top face). Exclude Z≈SPLIT_Z (the join edge).
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z_mid = (v0.Z + v1.Z) / 2.0
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if dx > L * 0.5 and dz < 0.5 and dy < 0.5 and z_mid > H - 1.0:
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th_edges.append(e)
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@@ -312,20 +324,15 @@ try:
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except Exception as exc:
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print(f"Top shell horizontal fillet skipped: {exc}")
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# 2. Inner cavity: side walls WALL thick, CEILING at H-WALL (WALL-thick roof),
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# FLOOR open (starts at SPLIT_Z — nothing blocks the bottom opening).
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# Cavity box: X from WALL→L-WALL, Y from WALL→W-WALL, Z from SPLIT_Z→H-WALL
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# 2. Inner cavity
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top_cav_lx = L - WALL * 2
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top_cav_ly = W - WALL * 2
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top_cav_lz = top_h - WALL # = 7.5 - 3.5 = 4.0 mm interior height
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top_cav_lz = top_h - WALL
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top_inner = box(top_cav_lx, top_cav_ly, top_cav_lz,
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WALL, WALL, SPLIT_Z) # starts exactly at SPLIT_Z
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WALL, WALL, SPLIT_Z)
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top_shell = top_outer.cut(top_inner)
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# 3. Groove at the bottom of the top shell, starting at SPLIT_Z
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# The groove is a frame-shaped recess cut into the inner face of the walls.
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# It goes from Z=SPLIT_Z up to Z=SPLIT_Z+GROOVE_H.
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# Width = GROOVE_T (slightly wider than tongue).
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# 3. Groove at the bottom of the top shell
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g_slab = box(top_cav_lx, top_cav_ly, GROOVE_H,
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WALL, WALL, SPLIT_Z)
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g_cut = box(top_cav_lx - GROOVE_T*2, top_cav_ly - GROOVE_T*2, GROOVE_H + 1,
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@@ -333,12 +340,35 @@ g_cut = box(top_cav_lx - GROOVE_T*2, top_cav_ly - GROOVE_T*2, GROOVE_H + 1,
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groove = g_slab.cut(g_cut)
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top_shell = top_shell.cut(groove)
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# 4. Button aperture — brute-force: run cylinder from Z=SPLIT_Z to Z=H+2.
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# It will punch through the ceiling regardless of any topology.
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# 4. Ridge recess in the groove wall — matches the snap ridges on the tongue.
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# The groove outer wall in -Y direction is the inner face of the top shell
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# wall at Y=WALL. The recess is cut OUTWARD from the groove wall face,
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# i.e. the wall material between groove and outside.
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#
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# Recess for -Y groove wall face (inner face sits at Y = WALL + GROOVE_T):
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# We need to cut from the groove outer face inward.
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# The groove outer face (toward -Y) is at Y = WALL.
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# Recess: box RIDGE_W wide in X, RIDGE_PROUD + TOL deep in Y (into wall),
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# RIDGE_H + TOL tall, at ridge_z0.
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#
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# Note: the groove wall is only GROOVE_T = 1.45 mm wide; cutting RIDGE_PROUD
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# (0.4 mm) + TOL (0.25 mm) = 0.65 mm is well within that.
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#
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recess_depth = RIDGE_PROUD + TOL
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recess_h = RIDGE_H + TOL
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recess_z0 = ridge_z0 - TOL / 2.0 # slight vertical oversize for tolerance
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recess_neg_y = box(RIDGE_W, recess_depth, recess_h,
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ridge_x0, WALL - recess_depth, recess_z0)
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recess_pos_y = box(RIDGE_W, recess_depth, recess_h,
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ridge_x0, W - WALL, recess_z0)
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top_shell = top_shell.cut(recess_neg_y).cut(recess_pos_y)
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# 5. Button aperture — brute-force punch through ceiling
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top_shell = top_shell.cut(
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cyl(BTN_HOLE_R, H - SPLIT_Z + 2, BTN_X, BTN_CY, SPLIT_Z))
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# 5. Button PCB shelf frame
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# 6. Button PCB shelf frame
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shelf_ox = BTN_X - BPCB_L / 2.0
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shelf_oy = BTN_CY - BPCB_W / 2.0
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shelf_h = 1.5
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@@ -351,13 +381,17 @@ shelf = shelf_slab.cut(shelf_hole)
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if floor_top_shell < PCB_BOT_Z < H - WALL:
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top_shell = top_shell.fuse(shelf)
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# 6. Screw posts on top-shell floor
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# 7. Four screw posts (2×2 grid) for button daughterboard
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# Grid centred at (BTN_X, BTN_CY), 2 mm pitch → offsets ±POST_OFFS
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if POST_H > 0.5:
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for py in [BTN_CY - POST_SEP/2.0, BTN_CY + POST_SEP/2.0]:
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p = cyl(POST_R, POST_H, BTN_X, py, floor_top_shell)
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ph = cyl(POST_IR, POST_H + 1.0, BTN_X, py, floor_top_shell)
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top_shell = top_shell.fuse(p)
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top_shell = top_shell.cut(ph)
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for px_off in [-POST_OFFS, +POST_OFFS]:
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for py_off in [-POST_OFFS, +POST_OFFS]:
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px = BTN_X + px_off
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py = BTN_CY + py_off
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p = cyl(POST_R, POST_H, px, py, floor_top_shell)
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ph = cyl(POST_IR, POST_H + 1.0, px, py, floor_top_shell)
|
||||
top_shell = top_shell.fuse(p)
|
||||
top_shell = top_shell.cut(ph)
|
||||
|
||||
# ═════════════════════════════════════════════════════════════════════════════
|
||||
# BUTTON CAP (separate printed part)
|
||||
@@ -368,14 +402,11 @@ if POST_H > 0.5:
|
||||
# Nubbin: Z = -CAP_RIM_H-NUBBIN_H → Z = -CAP_RIM_H
|
||||
#
|
||||
# Placed so shaft top = H → flush with top face.
|
||||
# Rim is entirely inside the cavity. No part protrudes above H.
|
||||
# ═════════════════════════════════════════════════════════════════════════════
|
||||
cap_shaft = cyl(CAP_SHAFT_R, CAP_SHAFT_H)
|
||||
cap_rim = cyl(CAP_RIM_R, CAP_RIM_H, 0, 0, -CAP_RIM_H)
|
||||
cap_nub = cyl(NUBBIN_R, NUBBIN_H, 0, 0, -CAP_RIM_H - NUBBIN_H)
|
||||
cap_raw = cap_shaft.fuse(cap_rim).fuse(cap_nub)
|
||||
# No fillet on cap top rim — cap sits flush inside aperture so a fillet
|
||||
# would create a visible chamfer ring against the hole edge.
|
||||
cap_placed = cap_raw.copy()
|
||||
cap_placed.translate(Base.Vector(BTN_X, BTN_CY, H - CAP_SHAFT_H))
|
||||
|
||||
@@ -405,7 +436,7 @@ Gui.SendMsgToActiveView("ViewFit")
|
||||
# SUMMARY
|
||||
# ═════════════════════════════════════════════════════════════════════════════
|
||||
print("=" * 62)
|
||||
print("IMU Pointer v7")
|
||||
print("IMU Pointer v8")
|
||||
print("=" * 62)
|
||||
print(f"Body: {L:.0f} × {W:.0f} mm")
|
||||
print(f"Height: {H:.0f} mm uniform (no taper)")
|
||||
@@ -416,15 +447,18 @@ print(f"Top shell interior height: {top_cav_lz:.1f} mm (Z {SPLIT_Z:.1f} → {H
|
||||
print()
|
||||
print(f"Tongue H/T: {TONGUE_H:.1f} / {TONGUE_T:.1f} mm")
|
||||
print(f"Groove H/T: {GROOVE_H:.2f} / {GROOVE_T:.2f} mm")
|
||||
print(f"Snap ridge: {RIDGE_W:.0f} mm long × {RIDGE_H:.1f} mm tall × {RIDGE_PROUD:.1f} mm proud")
|
||||
print(f"Ridge recess: {RIDGE_W:.0f} mm long × {recess_h:.2f} mm tall × {recess_depth:.2f} mm deep")
|
||||
print()
|
||||
print(f"Button hole: ⌀{BTN_HOLE_R*2:.0f} mm X={BTN_X} Y={BTN_CY:.0f}")
|
||||
print(f"Button hole: ⌀{BTN_HOLE_R*2:.0f} mm X={BTN_X} Y={BTN_CY:.0f} (was ⌀16 mm)")
|
||||
print(f"Cap shaft: ⌀{CAP_SHAFT_R*2:.1f} mm × {CAP_SHAFT_H:.1f} mm (flush, Z {H-WALL:.1f}→{H:.1f})")
|
||||
print(f"Cap rim: ⌀{CAP_RIM_R*2:.0f} mm × {CAP_RIM_H:.1f} mm (retention, below top face)")
|
||||
print(f"Cap rim: ⌀{CAP_RIM_R*2:.0f} mm × {CAP_RIM_H:.1f} mm (retention)")
|
||||
print()
|
||||
print(f"PCB top Z: {PCB_TOP_Z:.2f} mm (above split floor {floor_top_shell:.1f} mm)")
|
||||
print(f"PCB bot Z: {PCB_BOT_Z:.2f} mm")
|
||||
print(f"Post H: {POST_H:.2f} mm ⌀{POST_OD:.0f}/{POST_ID:.1f} mm sep={POST_SEP:.0f} mm c-to-c")
|
||||
print(f"Post H: {POST_H:.2f} mm ⌀{POST_OD:.0f}/{POST_ID:.1f} mm pitch={POST_PITCH:.0f} mm")
|
||||
print(f"Posts (4×): (BTN_X±{POST_OFFS:.0f}, BTN_CY±{POST_OFFS:.0f})")
|
||||
print()
|
||||
print(f"Switch stack: body={SWITCH_BODY_H} + stem={STEM_H} + gap={GAP} mm")
|
||||
print(" Adjust SWITCH_BODY_H / STEM_H if your Omron differs.")
|
||||
print("=" * 62)
|
||||
print("=" * 62)
|
||||
|
||||
Reference in New Issue
Block a user