diff --git a/model/pointer.FCMacro b/model/pointer.FCMacro index 5530bbf..9211f14 100644 --- a/model/pointer.FCMacro +++ b/model/pointer.FCMacro @@ -1,37 +1,35 @@ """ -IMU Pointer Enclosure — v6 +IMU Pointer Enclosure — v8 ============================ -Fixes from v5 (diagnosed from rendered images): +Changes from v7: - 1. BOTTOM HOLE: - v5 built the bottom shell from a full-height box (0→H) then trimmed - at SPLIT_Z. The taper wedge interacted badly with the split cut near - X=0 leaving a hole in the floor. Fix: build bottom outer solid only - to SPLIT_Z height — no trimming step needed, no interaction. + 1. SNAP-LOCK JOINT: + Removed the flex notches that were cutting through the tongue (they were + weakening it without providing any positive lock). Replaced with a snap + ridge system: a small rectangular bump is added to the OUTER face of the + tongue on each long side at mid-tongue height. The top-shell groove gets a + matching recess (undercut) so the ridge clicks in when the top is pushed + down. To release, flex the shell sides slightly outward. - 2. TOP SHELL WALLS PROTRUDING BELOW SPLIT: - v5 top_outer started at SPLIT_Z but the cavity inside started at - SPLIT_Z + WALL, leaving WALL=3.5mm of solid wall below the groove — - visually protruding past the bottom shell. Fix: the top shell outer - solid starts at SPLIT_Z. The groove is cut starting exactly at SPLIT_Z - so there is zero protrusion below the split line. + 2. LARGER BUTTON APERTURE: + BTN_HOLE_R increased from 8 mm → 10 mm (⌀20 mm contact face). + Cap shaft/rim scale accordingly. Makes it much harder to miss the button. - 3. BUTTON CAP NOT FLUSH / SITTING PROUD: - Aperture cylinder had arithmetic-derived Z that could miss the top wall - faces after filleting. Fix: aperture runs from Z=SPLIT_Z (well inside - the cavity) all the way to Z=H+2 — brute-force punch, impossible to miss. - - 4. CAP RIM SITS UNDER OUTER FACE (not above it): - Cap is placed so shaft top = H (flush). Rim hangs BELOW the top face - inside the cavity — correct retention geometry. The cap shaft top is - exactly flush with H. No part of the cap protrudes above H. + 3. FOUR SCREW POSTS FOR BUTTON DAUGHTERBOARD: + Previous design had 2 posts only in Y. Replaced with 4 posts in a 2×2 + grid centred under the button. Pin pitch 2 mm c-to-c → posts at + (BTN_X ± 1 mm, BTN_CY ± 1 mm). Screw hole ⌀0.9 mm (just under 1 mm), + post OD 4 mm for adequate wall thickness around the hole. Split joint design: - - Bottom shell has a TONGUE that projects UP from SPLIT_Z. - The tongue is a thin rectangular frame (inner perimeter of the walls). - - Top shell has a matching GROOVE cut into the inside of its lower edge, - starting exactly at SPLIT_Z (the bottom face of the top shell). - - Two flex notches cut through the tongue on the long sides allow snap fit. + - Bottom shell TONGUE projects UP from SPLIT_Z (thin rectangular frame). + - SNAP RIDGE: small box bump on the outer long-side faces of the tongue, + at ~mid tongue height. Ridge stands proud of the tongue outer face by + RIDGE_PROUD (0.4 mm), so the groove wall deflects it inward during + insertion and snaps into RIDGE_RECESS cut into the groove wall. + - Top shell GROOVE cut into the inside of its lower edge. + - RIDGE RECESS: matching pocket cut into the outer face of the groove to + receive the snap ridge. """ import FreeCAD as App @@ -40,7 +38,7 @@ import Part import math from FreeCAD import Base -doc = App.newDocument("pointer_v7") +doc = App.newDocument("pointer_v8") # ───────────────────────────────────────────────────────────────────────────── # DIMENSIONS @@ -48,13 +46,12 @@ doc = App.newDocument("pointer_v7") L = 115.0 # length (X): front=0, back=L W = 36.0 # width (Y) H = 22.0 # height (Z): bottom=0, top=H -WALL = 4.5 # wall thickness (+1 mm vs v6 — closes taper floor gap) +WALL = 4.5 # wall thickness CR = 5.0 # corner fillet radius (vertical edges) TOL = 0.25 # fit tolerance -# Taper: front of bottom shell is TAPER_RISE mm shorter than back. -# Applied only to the BOTTOM shell (it's where the ergonomic taper lives). -TAPER_RISE = 0.0 # no taper — removed per user request +# Taper: removed per user request +TAPER_RISE = 0.0 TAPER_LEN = 100.0 # unused but kept to avoid NameError # Split plane @@ -69,9 +66,13 @@ TONGUE_T = 1.2 # tongue wall thickness GROOVE_H = TONGUE_H + TOL GROOVE_T = TONGUE_T + TOL -# Flex notch through tongue (for snap release) -NOTCH_W = 8.0 -NOTCH_H = TONGUE_H + 0.5 +# Snap ridge on tongue long sides +# Ridge sits on the OUTER face of the tongue (the face against the groove wall) +# at mid-tongue height. The groove wall has a matching recess. +RIDGE_W = 12.0 # length of ridge along X (centred on enclosure) +RIDGE_H = 0.8 # height of the ridge bump +RIDGE_PROUD = 0.4 # how far ridge protrudes beyond tongue outer face +RIDGE_Z_OFF = (TONGUE_H - RIDGE_H) / 2.0 # centres ridge vertically in tongue # ───────────────────────────────────────────────────────────────────────────── # IMU BOARD @@ -99,16 +100,16 @@ BAT_Y = (W - BAT_W) / 2.0 BAT_CLIP_Y = 8.0 # ───────────────────────────────────────────────────────────────────────────── -# BUTTON +# BUTTON — enlarged aperture for easier contact # ───────────────────────────────────────────────────────────────────────────── BTN_X = 28.0 BTN_CY = W / 2.0 -BTN_HOLE_R = 8.0 -CAP_SHAFT_R = BTN_HOLE_R - 0.4 # 0.4 mm radial clearance in hole -CAP_SHAFT_H = WALL # shaft fills top wall → top face flush -CAP_RIM_R = BTN_HOLE_R + 2.0 # 2 mm wider than hole → retention +BTN_HOLE_R = 10.0 # ⌀20 mm — up from ⌀16 mm for easier press +CAP_SHAFT_R = BTN_HOLE_R - 0.4 # 0.4 mm radial clearance +CAP_SHAFT_H = WALL # shaft fills top wall → top face flush +CAP_RIM_R = BTN_HOLE_R + 2.0 # 2 mm wider than hole → retention CAP_RIM_H = 1.5 -NUBBIN_R = 1.8 +NUBBIN_R = 2.2 # slightly larger nubbin to match bigger cap NUBBIN_H = 2.0 # Switch geometry (adjust to match your Omron) @@ -126,9 +127,14 @@ if PCB_BOT_Z < floor_top_shell + 0.5: PCB_TOP_Z = PCB_BOT_Z + PCB_T POST_H = PCB_BOT_Z - floor_top_shell -POST_OD = 4.0; POST_R = POST_OD / 2.0 -POST_ID = 1.9; POST_IR = POST_ID / 2.0 -POST_SEP = 3.0 + +# ── Screw posts ────────────────────────────────────────────────────────────── +# 4 posts in a 2×2 grid centred under the button. +# Pin pitch 2 mm c-to-c → offsets ±1 mm in both X and Y from button centre. +POST_OD = 4.0; POST_R = POST_OD / 2.0 +POST_ID = 0.9; POST_IR = POST_ID / 2.0 # just under ⌀1 mm +POST_PITCH = 2.0 # 2 mm centre-to-centre +POST_OFFS = POST_PITCH / 2.0 # ±1 mm from centre BPCB_L = 16.0 BPCB_W = 16.0 @@ -204,10 +210,8 @@ def make_clip(cx, cy, ix, iy): bot_outer = box(L, W, SPLIT_Z) bot_outer = fillet_vert(bot_outer, CR, min_len=SPLIT_Z * 0.4) -# Fillet the long horizontal edges the user holds. -# These are the 4 edges running in X at Z≈0 and Z≈SPLIT_Z, on both long sides. -# Same fillet applied to equivalent edges on the top shell later. -EDGE_FILLET = 2.5 # mm — soft and comfortable, visible but not decorative +# Fillet the bottom long horizontal edges (comfort grip) +EDGE_FILLET = 2.5 try: h_edges = [] for e in bot_outer.Edges: @@ -217,8 +221,6 @@ try: dx = abs(v0.X - v1.X) dz = abs(v0.Z - v1.Z) dy = abs(v0.Y - v1.Y) - # Long edge in X, horizontal, on a long side face — - # but ONLY at Z≈0 (bottom face). Exclude Z≈SPLIT_Z (the join edge). z_mid = (v0.Z + v1.Z) / 2.0 if dx > L * 0.5 and dz < 0.5 and dy < 0.5 and z_mid < 1.0: h_edges.append(e) @@ -230,33 +232,47 @@ try: except Exception as exc: print(f"Bottom shell horizontal fillet skipped: {exc}") -# No taper wedge — removed per user request - -# 3. Inner cavity — floor at WALL, ceiling at SPLIT_Z (open top, no ceiling) +# 3. Inner cavity bot_cav_lx = L - WALL * 2 bot_cav_ly = W - WALL * 2 -bot_cav_lz = SPLIT_Z - WALL # floor(WALL) → SPLIT_Z +bot_cav_lz = SPLIT_Z - WALL bot_inner = box(bot_cav_lx, bot_cav_ly, bot_cav_lz, WALL, WALL, WALL) bot_shell = bot_outer.cut(bot_inner) # 4. Tongue (projects UP from SPLIT_Z, inner perimeter frame) -# Outer edge of tongue = inner face of outer wall = WALL from outside -# Inner edge of tongue = WALL + TONGUE_T from outside t_slab = box(bot_cav_lx, bot_cav_ly, TONGUE_H, WALL, WALL, SPLIT_Z) t_cut = box(bot_cav_lx - TONGUE_T*2, bot_cav_ly - TONGUE_T*2, TONGUE_H + 1, WALL + TONGUE_T, WALL + TONGUE_T, SPLIT_Z - 0.5) tongue = t_slab.cut(t_cut) -# Flex notches on the two long sides (parallel to X) -nx0 = L / 2.0 - NOTCH_W / 2.0 -for ny_start in [WALL, W - WALL - TONGUE_T]: - tongue = tongue.cut( - box(NOTCH_W, TONGUE_T + 0.5, NOTCH_H, - nx0, ny_start - 0.1, SPLIT_Z - 0.1)) +# 5. Snap ridges on the tongue outer long-side faces +# The tongue outer face sits at Y=WALL and Y=W-WALL (bottom shell outer wall +# inner face). We add a small proud bump to each long side (the Y faces). +# +# Long sides run in X. The tongue outer face in -Y direction is at Y=WALL, +# outer face in +Y direction is at Y=W-WALL. +# +# Ridge box for -Y side: +# X: centred on L/2, width RIDGE_W +# Y: from (WALL - RIDGE_PROUD) to WALL (proud outward = -Y direction) +# Z: from (SPLIT_Z + RIDGE_Z_OFF) height RIDGE_H +# +# Ridge box for +Y side: +# Y: from (W - WALL) to (W - WALL + RIDGE_PROUD) +# +ridge_x0 = L / 2.0 - RIDGE_W / 2.0 +ridge_z0 = SPLIT_Z + RIDGE_Z_OFF + +ridge_neg_y = box(RIDGE_W, RIDGE_PROUD, RIDGE_H, + ridge_x0, WALL - RIDGE_PROUD, ridge_z0) +ridge_pos_y = box(RIDGE_W, RIDGE_PROUD, RIDGE_H, + ridge_x0, W - WALL, ridge_z0) +tongue = tongue.fuse(ridge_neg_y).fuse(ridge_pos_y) + bot_shell = bot_shell.fuse(tongue) -# 5. IMU clips +# 6. IMU clips for cx, cy, ix, iy in [ (BRD_X, BRD_Y, +1, +1), (BRD_X + BRD_L, BRD_Y, -1, +1), @@ -265,15 +281,14 @@ for cx, cy, ix, iy in [ ]: bot_shell = bot_shell.fuse(make_clip(cx, cy, ix, iy)) -# 6. USB-C slot — starts at X = -WALL*3 so it punches through the rounded -# front face cleanly regardless of fillet radius +# 7. USB-C slot bot_shell = bot_shell.cut( rounded_slot(WALL * 6, USBC_W, USBC_H, -WALL * 3, W / 2.0 - USBC_W / 2.0, USBC_Z)) -# 7. Battery bay +# 8. Battery bay bot_shell = bot_shell.cut(box(BAT_L, BAT_W, 3.0, BAT_X, BAT_Y, WALL)) cy0 = BAT_Y + BAT_W / 2.0 - BAT_CLIP_Y / 2.0 bot_shell = bot_shell.fuse(box(2.0, BAT_CLIP_Y, BAT_H * 0.55, BAT_X - 2.0, cy0, WALL)) @@ -288,8 +303,7 @@ top_h = H - SPLIT_Z # = 7.5 mm top_outer = box(L, W, top_h, 0, 0, SPLIT_Z) top_outer = fillet_vert(top_outer, CR, min_len=top_h * 0.4) -# Fillet the long horizontal edges of the top shell — -# the top edges (Z≈H) are the ones selected in blue in the user's screenshot. +# Fillet the top long horizontal edges try: th_edges = [] for e in top_outer.Edges: @@ -299,8 +313,6 @@ try: dx = abs(v0.X - v1.X) dz = abs(v0.Z - v1.Z) dy = abs(v0.Y - v1.Y) - # Long edge in X, horizontal, on a long side face — - # ONLY at Z≈H (top face). Exclude Z≈SPLIT_Z (the join edge). z_mid = (v0.Z + v1.Z) / 2.0 if dx > L * 0.5 and dz < 0.5 and dy < 0.5 and z_mid > H - 1.0: th_edges.append(e) @@ -312,20 +324,15 @@ try: except Exception as exc: print(f"Top shell horizontal fillet skipped: {exc}") -# 2. Inner cavity: side walls WALL thick, CEILING at H-WALL (WALL-thick roof), -# FLOOR open (starts at SPLIT_Z — nothing blocks the bottom opening). -# Cavity box: X from WALL→L-WALL, Y from WALL→W-WALL, Z from SPLIT_Z→H-WALL +# 2. Inner cavity top_cav_lx = L - WALL * 2 top_cav_ly = W - WALL * 2 -top_cav_lz = top_h - WALL # = 7.5 - 3.5 = 4.0 mm interior height +top_cav_lz = top_h - WALL top_inner = box(top_cav_lx, top_cav_ly, top_cav_lz, - WALL, WALL, SPLIT_Z) # starts exactly at SPLIT_Z + WALL, WALL, SPLIT_Z) top_shell = top_outer.cut(top_inner) -# 3. Groove at the bottom of the top shell, starting at SPLIT_Z -# The groove is a frame-shaped recess cut into the inner face of the walls. -# It goes from Z=SPLIT_Z up to Z=SPLIT_Z+GROOVE_H. -# Width = GROOVE_T (slightly wider than tongue). +# 3. Groove at the bottom of the top shell g_slab = box(top_cav_lx, top_cav_ly, GROOVE_H, WALL, WALL, SPLIT_Z) g_cut = box(top_cav_lx - GROOVE_T*2, top_cav_ly - GROOVE_T*2, GROOVE_H + 1, @@ -333,12 +340,35 @@ g_cut = box(top_cav_lx - GROOVE_T*2, top_cav_ly - GROOVE_T*2, GROOVE_H + 1, groove = g_slab.cut(g_cut) top_shell = top_shell.cut(groove) -# 4. Button aperture — brute-force: run cylinder from Z=SPLIT_Z to Z=H+2. -# It will punch through the ceiling regardless of any topology. +# 4. Ridge recess in the groove wall — matches the snap ridges on the tongue. +# The groove outer wall in -Y direction is the inner face of the top shell +# wall at Y=WALL. The recess is cut OUTWARD from the groove wall face, +# i.e. the wall material between groove and outside. +# +# Recess for -Y groove wall face (inner face sits at Y = WALL + GROOVE_T): +# We need to cut from the groove outer face inward. +# The groove outer face (toward -Y) is at Y = WALL. +# Recess: box RIDGE_W wide in X, RIDGE_PROUD + TOL deep in Y (into wall), +# RIDGE_H + TOL tall, at ridge_z0. +# +# Note: the groove wall is only GROOVE_T = 1.45 mm wide; cutting RIDGE_PROUD +# (0.4 mm) + TOL (0.25 mm) = 0.65 mm is well within that. +# +recess_depth = RIDGE_PROUD + TOL +recess_h = RIDGE_H + TOL +recess_z0 = ridge_z0 - TOL / 2.0 # slight vertical oversize for tolerance + +recess_neg_y = box(RIDGE_W, recess_depth, recess_h, + ridge_x0, WALL - recess_depth, recess_z0) +recess_pos_y = box(RIDGE_W, recess_depth, recess_h, + ridge_x0, W - WALL, recess_z0) +top_shell = top_shell.cut(recess_neg_y).cut(recess_pos_y) + +# 5. Button aperture — brute-force punch through ceiling top_shell = top_shell.cut( cyl(BTN_HOLE_R, H - SPLIT_Z + 2, BTN_X, BTN_CY, SPLIT_Z)) -# 5. Button PCB shelf frame +# 6. Button PCB shelf frame shelf_ox = BTN_X - BPCB_L / 2.0 shelf_oy = BTN_CY - BPCB_W / 2.0 shelf_h = 1.5 @@ -351,13 +381,17 @@ shelf = shelf_slab.cut(shelf_hole) if floor_top_shell < PCB_BOT_Z < H - WALL: top_shell = top_shell.fuse(shelf) -# 6. Screw posts on top-shell floor +# 7. Four screw posts (2×2 grid) for button daughterboard +# Grid centred at (BTN_X, BTN_CY), 2 mm pitch → offsets ±POST_OFFS if POST_H > 0.5: - for py in [BTN_CY - POST_SEP/2.0, BTN_CY + POST_SEP/2.0]: - p = cyl(POST_R, POST_H, BTN_X, py, floor_top_shell) - ph = cyl(POST_IR, POST_H + 1.0, BTN_X, py, floor_top_shell) - top_shell = top_shell.fuse(p) - top_shell = top_shell.cut(ph) + for px_off in [-POST_OFFS, +POST_OFFS]: + for py_off in [-POST_OFFS, +POST_OFFS]: + px = BTN_X + px_off + py = BTN_CY + py_off + p = cyl(POST_R, POST_H, px, py, floor_top_shell) + 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) \ No newline at end of file +print("=" * 62)