Redesign MCU and PCB mounting
This commit is contained in:
@@ -1,464 +1,190 @@
|
||||
"""
|
||||
IMU Pointer Enclosure — v8
|
||||
============================
|
||||
Changes from v7:
|
||||
|
||||
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. 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. 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 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.
|
||||
IMU Pointer Enclosure — v11.7 (Slimmed Corners & Rounded USB-C)
|
||||
"""
|
||||
|
||||
import FreeCAD as App
|
||||
import FreeCADGui as Gui
|
||||
import Part
|
||||
import math
|
||||
from FreeCAD import Base
|
||||
|
||||
doc = App.newDocument("pointer_v8")
|
||||
doc = App.newDocument("pointer_v11_7")
|
||||
|
||||
# ─────────────────────────────────────────────────────────────────────────────
|
||||
# DIMENSIONS
|
||||
# ─────────────────────────────────────────────────────────────────────────────
|
||||
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
|
||||
CR = 5.0 # corner fillet radius (vertical edges)
|
||||
TOL = 0.25 # fit tolerance
|
||||
# ─── DIMENSIONS ───────────────────────────────────────────────────────────────
|
||||
L, W, H = 115.0, 36.0, 22.0
|
||||
WALL = 3.5
|
||||
CR, CR_I = 8.0, 4.5
|
||||
TOL = 0.25
|
||||
EDGE_FILLET = 3.0
|
||||
|
||||
# Taper: removed per user request
|
||||
TAPER_RISE = 0.0
|
||||
TAPER_LEN = 100.0 # unused but kept to avoid NameError
|
||||
USBC_W, USBC_H, USBC_Z = 12.0, 7.0, 5.0
|
||||
SPLIT_Z = USBC_Z + USBC_H + 2.5
|
||||
|
||||
# Split plane
|
||||
USBC_W = 11.0
|
||||
USBC_H = 7.0
|
||||
USBC_Z = 5.0
|
||||
SPLIT_Z = USBC_Z + USBC_H + 2.5 # = 14.5 mm
|
||||
# MICRO-DETENT Snap Logic
|
||||
TONGUE_H, TONGUE_T = 2.5, 2.0
|
||||
GROOVE_H, GROOVE_T = TONGUE_H + TOL, TONGUE_T + TOL
|
||||
RIDGE_W = 12.0
|
||||
RIDGE_H = 1.2
|
||||
RIDGE_PROUD = 1.0 # Snap ridge protrusion
|
||||
RIDGE_Z_OFF = (TONGUE_H - RIDGE_H) / 2.0
|
||||
|
||||
# Tongue/groove clip joint
|
||||
TONGUE_H = 2.5 # how far tongue projects above SPLIT_Z
|
||||
TONGUE_T = 1.2 # tongue wall thickness
|
||||
GROOVE_H = TONGUE_H + TOL
|
||||
GROOVE_T = TONGUE_T + TOL
|
||||
# ─── IMU BOARD (+1mm Spacing & Slim Corners) ──────────────────────────────────
|
||||
PCB_T, BRD_L, BRD_W = 3.0, 22.6, 19.6
|
||||
BRD_X, BRD_Y = WALL, (W - BRD_W) / 2.0
|
||||
PLATFORM_H, MIC_EXTRA = 1.5, 2.0
|
||||
MIC_PCB_T = 2.5 # Thicker PCB section (MEMS mic), rounded up from 2.2
|
||||
BUMP_PROUD = 0.3 # Press-fit nub protrusion into board cavity
|
||||
BUMP_R = 0.6 # Nub radius (half-sphere)
|
||||
BRD_Z = WALL + PLATFORM_H
|
||||
|
||||
# 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
|
||||
# ─── BUTTON & BATTERY ─────────────────────────────────────────────────────────
|
||||
BAT_L, BAT_W, BAT_H = 50.0, 12.0, 12.0
|
||||
BAT_X, BAT_Y = BRD_X + BRD_L + 8.0 + 5.0, (W - BAT_W) / 2.0
|
||||
BAT_CLIP_Y = 8.0
|
||||
BTN_X, BTN_CY, BTN_HOLE_R = 28.0, W / 2.0, 10.0
|
||||
CAP_SHAFT_R, CAP_SHAFT_H = 9.6, WALL
|
||||
CAP_RIM_R, CAP_RIM_H = 12.0, 1.5
|
||||
NUBBIN_R, NUBBIN_H = 4.2, 1.0
|
||||
BTN_DOME_R, BTN_DOME_SAG = 14.0, 0.6
|
||||
|
||||
# ─────────────────────────────────────────────────────────────────────────────
|
||||
# IMU BOARD
|
||||
# ─────────────────────────────────────────────────────────────────────────────
|
||||
PCB_T = 1.0
|
||||
BRD_L = 21.0
|
||||
BRD_W = 17.5
|
||||
BRD_X = WALL
|
||||
BRD_Y = (W - BRD_W) / 2.0
|
||||
PLATFORM_H = 0.5
|
||||
BRD_Z = WALL + PLATFORM_H
|
||||
ARM_LEN = 5.0
|
||||
ARM_THICK = 1.6
|
||||
ARM_H = BRD_Z + PCB_T + 0.8
|
||||
CLIP_TOL = 0.35
|
||||
PCB_BOT_Z = SPLIT_Z + 1.5
|
||||
POST_H = BRD_Z + PCB_T + MIC_EXTRA + 3.0 - 4.0 # Lowered 4mm for button PCB + button thickness
|
||||
POST_OFFS_X, POST_OFFS_Y = 4.0, 11.0
|
||||
LH_R, LH_X, LH_Y_OFFS = 1.5, L - WALL - 3.0, 4.0
|
||||
BPCB_L, BPCB_W = 16.0, 16.0
|
||||
|
||||
# ─────────────────────────────────────────────────────────────────────────────
|
||||
# BATTERY BAY
|
||||
# ─────────────────────────────────────────────────────────────────────────────
|
||||
BAT_L = 50.0
|
||||
BAT_W = 12.0
|
||||
BAT_H = 12.0
|
||||
BAT_X = BRD_X + BRD_L + 8.0
|
||||
BAT_Y = (W - BAT_W) / 2.0
|
||||
BAT_CLIP_Y = 8.0
|
||||
# ─── HELPERS ──────────────────────────────────────────────────────────────────
|
||||
|
||||
# ─────────────────────────────────────────────────────────────────────────────
|
||||
# BUTTON — enlarged aperture for easier contact
|
||||
# ─────────────────────────────────────────────────────────────────────────────
|
||||
BTN_X = 28.0
|
||||
BTN_CY = W / 2.0
|
||||
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 = 2.2 # slightly larger nubbin to match bigger cap
|
||||
NUBBIN_H = 2.0
|
||||
|
||||
# Switch geometry (adjust to match your Omron)
|
||||
SWITCH_BODY_H = 5.0
|
||||
STEM_H = 2.5
|
||||
GAP = 0.5
|
||||
|
||||
# PCB position derived top-down
|
||||
PCB_TOP_Z = H - WALL - CAP_RIM_H - NUBBIN_H - GAP - SWITCH_BODY_H - STEM_H
|
||||
PCB_BOT_Z = PCB_TOP_Z - PCB_T
|
||||
# Clamp: must be inside the top shell cavity
|
||||
floor_top_shell = SPLIT_Z + WALL
|
||||
if PCB_BOT_Z < floor_top_shell + 0.5:
|
||||
PCB_BOT_Z = floor_top_shell + 0.5
|
||||
PCB_TOP_Z = PCB_BOT_Z + PCB_T
|
||||
|
||||
POST_H = PCB_BOT_Z - floor_top_shell
|
||||
|
||||
# ── 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
|
||||
SHELF_WALL = 2.0
|
||||
|
||||
# ─────────────────────────────────────────────────────────────────────────────
|
||||
# HELPERS
|
||||
# ─────────────────────────────────────────────────────────────────────────────
|
||||
|
||||
def box(lx, ly, lz, ox=0.0, oy=0.0, oz=0.0):
|
||||
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, cx=0.0, cy=0.0, cz=0.0):
|
||||
def rbox(lx, ly, lz, ox=0, oy=0, oz=0, r=CR):
|
||||
b = box(lx, ly, lz, ox, oy, oz)
|
||||
try:
|
||||
edges = [e for e in b.Edges if abs(e.Vertexes[0].X - e.Vertexes[1].X) < 1e-3 and abs(e.Vertexes[0].Y - e.Vertexes[1].Y) < 1e-3]
|
||||
return b.makeFillet(r, edges) if edges else b
|
||||
except: return b
|
||||
|
||||
def cyl(r, h, cx=0, cy=0, cz=0):
|
||||
return Part.makeCylinder(r, h, Base.Vector(cx, cy, cz))
|
||||
|
||||
def rounded_slot(depth, sw, sh, ox, oy, oz):
|
||||
"""Stadium slot extruded in +X."""
|
||||
r = min(sh / 2.0, sw / 2.0)
|
||||
cy = oy + sw / 2.0
|
||||
cz = oz + sh / 2.0
|
||||
hw = max(sw / 2.0 - r, 0.0)
|
||||
if hw < 1e-6:
|
||||
circ = Part.makeCircle(r, Base.Vector(ox, cy, cz), Base.Vector(1, 0, 0))
|
||||
return Part.Face(Part.Wire(circ)).extrude(Base.Vector(depth, 0, 0))
|
||||
l_s = Base.Vector(ox, cy - hw, cz - r)
|
||||
l_m = Base.Vector(ox, cy - hw - r, cz)
|
||||
l_e = Base.Vector(ox, cy - hw, cz + r)
|
||||
r_s = Base.Vector(ox, cy + hw, cz + r)
|
||||
r_m = Base.Vector(ox, cy + hw + r, cz)
|
||||
r_e = Base.Vector(ox, cy + hw, cz - r)
|
||||
wire = Part.Wire([Part.Arc(l_s, l_m, l_e).toShape(),
|
||||
Part.makeLine(l_e, r_s),
|
||||
Part.Arc(r_s, r_m, r_e).toShape(),
|
||||
Part.makeLine(r_e, l_s)])
|
||||
return Part.Face(wire).extrude(Base.Vector(depth, 0, 0))
|
||||
|
||||
def fillet_vert(solid, r, min_len=4.0):
|
||||
"""Fillet edges that are primarily vertical (parallel to Z)."""
|
||||
def fillet_horiz(solid, r, z_test):
|
||||
try:
|
||||
edges = [e for e in solid.Edges
|
||||
if len(e.Vertexes) == 2
|
||||
and abs(e.Vertexes[0].X - e.Vertexes[1].X) < 1e-3
|
||||
and abs(e.Vertexes[0].Y - e.Vertexes[1].Y) < 1e-3
|
||||
and e.Length >= min_len]
|
||||
if edges:
|
||||
return solid.makeFillet(r, edges)
|
||||
except Exception as e:
|
||||
print(f" fillet_vert skipped: {e}")
|
||||
return solid
|
||||
edges = [e for e in solid.Edges if abs(e.Vertexes[0].Z - e.Vertexes[1].Z) < 0.2 and abs((e.Vertexes[0].Z + e.Vertexes[1].Z)/2 - z_test) < 1.5]
|
||||
return solid.makeFillet(r, edges) if edges else solid
|
||||
except: return solid
|
||||
|
||||
def make_clip(cx, cy, ix, iy):
|
||||
plat_w = ARM_THICK + CLIP_TOL
|
||||
plat_x = cx if ix > 0 else cx - plat_w
|
||||
plat_y = cy if iy > 0 else cy - plat_w
|
||||
plat = box(plat_w, plat_w, PLATFORM_H + PCB_T, plat_x, plat_y, WALL)
|
||||
ax_ox = cx if ix > 0 else cx - ARM_LEN
|
||||
ax_oy = cy - ARM_THICK - CLIP_TOL if iy > 0 else cy + CLIP_TOL
|
||||
arm_x = box(ARM_LEN, ARM_THICK, ARM_H, ax_ox, ax_oy, WALL)
|
||||
ay_oy = cy if iy > 0 else cy - ARM_LEN
|
||||
ay_ox = cx - ARM_THICK - CLIP_TOL if ix > 0 else cx + CLIP_TOL
|
||||
arm_y = box(ARM_THICK, ARM_LEN, ARM_H, ay_ox, ay_oy, WALL)
|
||||
cb_w = ARM_THICK + CLIP_TOL
|
||||
cb_ox = cx - cb_w if ix > 0 else cx
|
||||
cb_oy = cy - cb_w if iy > 0 else cy
|
||||
cb = box(cb_w, cb_w, ARM_H, cb_ox, cb_oy, WALL)
|
||||
return plat.fuse(arm_x.fuse(arm_y).fuse(cb))
|
||||
def make_slim_corner(cx, cy, ix, iy):
|
||||
pw = 0.8 # Much slimmer wall thickness (was 1.5/1.6)
|
||||
sl = 4.0 # Slightly shorter side length
|
||||
h = PLATFORM_H + PCB_T + 0.5
|
||||
|
||||
x0, y0 = (cx if ix>0 else cx-sl), (cy if iy>0 else cy-pw)
|
||||
w1 = box(sl, pw, h, x0, y0, WALL)
|
||||
|
||||
x1, y1 = (cx if ix>0 else cx-pw), (cy if iy>0 else cy-sl)
|
||||
w2 = box(pw, sl, h, x1, y1, WALL)
|
||||
|
||||
px, py = (cx if ix>0 else cx-sl), (cy if iy>0 else cy-sl)
|
||||
plat = box(sl, sl, PLATFORM_H, px, py, WALL)
|
||||
|
||||
return plat.fuse(w1).fuse(w2)
|
||||
|
||||
# ═════════════════════════════════════════════════════════════════════════════
|
||||
# BOTTOM SHELL (Z = 0 → SPLIT_Z, open on top)
|
||||
# CONSTRUCTION
|
||||
# ═════════════════════════════════════════════════════════════════════════════
|
||||
|
||||
# 1. Outer solid — built ONLY to SPLIT_Z height
|
||||
bot_outer = box(L, W, SPLIT_Z)
|
||||
bot_outer = fillet_vert(bot_outer, CR, min_len=SPLIT_Z * 0.4)
|
||||
# BOTTOM SHELL
|
||||
bot_shell = fillet_horiz(rbox(L, W, SPLIT_Z + TONGUE_H), EDGE_FILLET, 0.0)
|
||||
bot_shell = bot_shell.cut(rbox(L-WALL*2, W-WALL*2, SPLIT_Z, WALL, WALL, WALL, r=CR_I))
|
||||
bot_shell = bot_shell.cut(rbox(L-TONGUE_T*2, W-TONGUE_T*2, TONGUE_H+2, TONGUE_T, TONGUE_T, SPLIT_Z, r=CR-TONGUE_T))
|
||||
|
||||
# Fillet the bottom long horizontal edges (comfort grip)
|
||||
EDGE_FILLET = 2.5
|
||||
try:
|
||||
h_edges = []
|
||||
for e in bot_outer.Edges:
|
||||
if len(e.Vertexes) != 2:
|
||||
continue
|
||||
v0, v1 = e.Vertexes[0], e.Vertexes[1]
|
||||
dx = abs(v0.X - v1.X)
|
||||
dz = abs(v0.Z - v1.Z)
|
||||
dy = abs(v0.Y - v1.Y)
|
||||
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)
|
||||
if h_edges:
|
||||
bot_outer = bot_outer.makeFillet(EDGE_FILLET, h_edges)
|
||||
print(f"Bottom shell: filleted {len(h_edges)} horizontal edge(s) R={EDGE_FILLET}")
|
||||
# Internal Fusions (Using Slim L-bracket style for MCU)
|
||||
for cx, cy, ix, iy in [(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)]:
|
||||
bot_shell = bot_shell.fuse(make_slim_corner(cx, cy, ix, iy))
|
||||
|
||||
# Press-fit nubs — half-sphere on each L-bracket's inner Y-facing wall (w1)
|
||||
bump_z = BRD_Z + 1.0 + BUMP_R # Bottom of nub sits 1mm above platform
|
||||
pw = 0.8; sl = 4.0 # Must match make_slim_corner
|
||||
for cx, cy, ix, iy in [(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)]:
|
||||
# w1 wall centre X: midpoint of the sl-long wall extending from corner
|
||||
mid_x = cx + ix * sl / 2.0
|
||||
# w1 inner face Y: the face that looks toward the board centre
|
||||
face_y = cy if iy > 0 else cy - pw # wall origin Y
|
||||
inner_y = face_y + pw if iy > 0 else face_y # the side facing inward
|
||||
# iy>0 → bump faces +Y (inward), iy<0 → bump faces -Y (inward)
|
||||
# Actually: iy>0 means corner is at low-Y side, wall inner face = face_y+pw, bump goes +Y
|
||||
# iy<0 means corner is at high-Y side, wall inner face = face_y, bump goes -Y
|
||||
sph = Part.makeSphere(BUMP_R, Base.Vector(mid_x, inner_y, bump_z))
|
||||
cs = BUMP_R + 0.5
|
||||
# Clip: keep only the half protruding inward (toward board centre)
|
||||
if iy > 0:
|
||||
clip = box(cs*2, cs, cs*2, mid_x - cs, inner_y, bump_z - cs)
|
||||
else:
|
||||
print("Bottom shell: no horizontal edges found — skipped")
|
||||
except Exception as exc:
|
||||
print(f"Bottom shell horizontal fillet skipped: {exc}")
|
||||
clip = box(cs*2, cs, cs*2, mid_x - cs, inner_y - cs, bump_z - cs)
|
||||
half_sph = sph.common(clip)
|
||||
bot_shell = bot_shell.fuse(half_sph)
|
||||
|
||||
# 3. Inner cavity
|
||||
bot_cav_lx = L - WALL * 2
|
||||
bot_cav_ly = W - WALL * 2
|
||||
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)
|
||||
POST_R = 1.75
|
||||
POST_TAPER_EXTRA = 0.3 # Extra radius at base
|
||||
POST_TAPER_H = 6.0 # Height over which the taper blends to nominal radius
|
||||
for px, py in [(BTN_X+ox, BTN_CY+oy) for ox in [-POST_OFFS_X, POST_OFFS_X] for oy in [-POST_OFFS_Y, POST_OFFS_Y]]:
|
||||
post = cyl(POST_R, POST_H, px, py, WALL)
|
||||
# Tapered cone base: wider at bottom, blends to post radius at POST_TAPER_H
|
||||
taper = Part.makeCone(POST_R + POST_TAPER_EXTRA, POST_R, POST_TAPER_H,
|
||||
Base.Vector(px, py, WALL))
|
||||
post = post.fuse(taper)
|
||||
post = post.cut(cyl(0.5, POST_H + 1, px, py, WALL))
|
||||
bot_shell = bot_shell.fuse(post)
|
||||
|
||||
# 4. Tongue (projects UP from SPLIT_Z, inner perimeter frame)
|
||||
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)
|
||||
# Rounded USB-C Cut (Pill Shape)
|
||||
usbc_r = USBC_H / 2.0
|
||||
usbc_box = box(WALL*4, USBC_W - 2*usbc_r, USBC_H, -1, W/2 - USBC_W/2 + usbc_r, USBC_Z)
|
||||
usbc_cyl1 = Part.makeCylinder(usbc_r, WALL*4, Base.Vector(-1, W/2 - USBC_W/2 + usbc_r, USBC_Z + usbc_r), Base.Vector(1, 0, 0))
|
||||
usbc_cyl2 = Part.makeCylinder(usbc_r, WALL*4, Base.Vector(-1, W/2 + USBC_W/2 - usbc_r, USBC_Z + usbc_r), Base.Vector(1, 0, 0))
|
||||
usbc_rounded = usbc_box.fuse(usbc_cyl1).fuse(usbc_cyl2)
|
||||
bot_shell = bot_shell.cut(usbc_rounded)
|
||||
|
||||
# 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)
|
||||
|
||||
# 6. IMU clips
|
||||
for cx, cy, ix, iy in [
|
||||
(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),
|
||||
]:
|
||||
bot_shell = bot_shell.fuse(make_clip(cx, cy, ix, iy))
|
||||
|
||||
# 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))
|
||||
|
||||
# 8. Battery bay
|
||||
# Battery bay + retaining tabs
|
||||
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))
|
||||
bot_shell = bot_shell.fuse(box(2.0, BAT_CLIP_Y, BAT_H * 0.55, BAT_X + BAT_L, cy0, WALL))
|
||||
bat_clip_cy = 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, bat_clip_cy, WALL))
|
||||
bot_shell = bot_shell.fuse(box(2.0, BAT_CLIP_Y, BAT_H * 0.55, BAT_X + BAT_L, bat_clip_cy, WALL))
|
||||
|
||||
# ═════════════════════════════════════════════════════════════════════════════
|
||||
# TOP SHELL (Z = SPLIT_Z → H, open on bottom, closed ceiling at H)
|
||||
# ═════════════════════════════════════════════════════════════════════════════
|
||||
top_h = H - SPLIT_Z # = 7.5 mm
|
||||
# MICRO-DETENT RIDGES: Buried deep, barely protruding
|
||||
rx0, rz0 = L/2 - RIDGE_W/2, SPLIT_Z + RIDGE_Z_OFF
|
||||
ridge_bury = 1.5
|
||||
ridge_total_t = ridge_bury + RIDGE_PROUD
|
||||
bot_shell = bot_shell.fuse(box(RIDGE_W, ridge_total_t, RIDGE_H, rx0, TONGUE_T - ridge_bury, rz0))
|
||||
bot_shell = bot_shell.fuse(box(RIDGE_W, ridge_total_t, RIDGE_H, rx0, W - TONGUE_T - RIDGE_PROUD, rz0))
|
||||
|
||||
# 1. Outer solid spans SPLIT_Z → H
|
||||
top_outer = box(L, W, top_h, 0, 0, SPLIT_Z)
|
||||
top_outer = fillet_vert(top_outer, CR, min_len=top_h * 0.4)
|
||||
# TOP SHELL
|
||||
top_shell = fillet_horiz(rbox(L, W, H-SPLIT_Z, 0, 0, SPLIT_Z), EDGE_FILLET, H)
|
||||
top_shell = top_shell.cut(rbox(L-WALL*2, W-WALL*2, H-SPLIT_Z-WALL, WALL, WALL, SPLIT_Z, r=CR_I))
|
||||
|
||||
# Fillet the top long horizontal edges
|
||||
try:
|
||||
th_edges = []
|
||||
for e in top_outer.Edges:
|
||||
if len(e.Vertexes) != 2:
|
||||
continue
|
||||
v0, v1 = e.Vertexes[0], e.Vertexes[1]
|
||||
dx = abs(v0.X - v1.X)
|
||||
dz = abs(v0.Z - v1.Z)
|
||||
dy = abs(v0.Y - v1.Y)
|
||||
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)
|
||||
if th_edges:
|
||||
top_outer = top_outer.makeFillet(EDGE_FILLET, th_edges)
|
||||
print(f"Top shell: filleted {len(th_edges)} horizontal edge(s) R={EDGE_FILLET}")
|
||||
else:
|
||||
print("Top shell: no horizontal edges found — skipped")
|
||||
except Exception as exc:
|
||||
print(f"Top shell horizontal fillet skipped: {exc}")
|
||||
# Groove and Matching Recesses
|
||||
g_band = rbox(L, W, GROOVE_H, 0, 0, SPLIT_Z, r=CR).cut(rbox(L-GROOVE_T*2, W-GROOVE_T*2, GROOVE_H+2, GROOVE_T, GROOVE_T, SPLIT_Z-1, r=CR-GROOVE_T))
|
||||
top_shell = top_shell.cut(g_band)
|
||||
|
||||
# 2. Inner cavity
|
||||
top_cav_lx = L - WALL * 2
|
||||
top_cav_ly = W - WALL * 2
|
||||
top_cav_lz = top_h - WALL
|
||||
top_inner = box(top_cav_lx, top_cav_ly, top_cav_lz,
|
||||
WALL, WALL, SPLIT_Z)
|
||||
top_shell = top_outer.cut(top_inner)
|
||||
# Recesses in groove wall — bottom ridges click into these
|
||||
rec_w = RIDGE_W + TOL*2
|
||||
rec_d = RIDGE_PROUD + TOL # Slightly deeper than ridge protrusion
|
||||
top_shell = top_shell.cut(box(rec_w, rec_d, RIDGE_H+TOL, L/2-rec_w/2, GROOVE_T, rz0-TOL/2))
|
||||
top_shell = top_shell.cut(box(rec_w, rec_d, RIDGE_H+TOL, L/2-rec_w/2, W-GROOVE_T-rec_d, rz0-TOL/2))
|
||||
|
||||
# 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,
|
||||
WALL + GROOVE_T, WALL + GROOVE_T, SPLIT_Z - 0.5)
|
||||
groove = g_slab.cut(g_cut)
|
||||
top_shell = top_shell.cut(groove)
|
||||
# Button & Cap
|
||||
top_shell = top_shell.cut(cyl(BTN_HOLE_R, H, BTN_X, BTN_CY, SPLIT_Z))
|
||||
top_shell = top_shell.cut(Part.makeSphere(BTN_DOME_R, Base.Vector(BTN_X, BTN_CY, H - WALL - BTN_DOME_R + BTN_DOME_SAG)))
|
||||
cap = cyl(CAP_SHAFT_R, CAP_SHAFT_H).fuse(cyl(CAP_RIM_R, CAP_RIM_H, 0, 0, -CAP_RIM_H)).fuse(cyl(NUBBIN_R, NUBBIN_H, 0, 0, -CAP_RIM_H - NUBBIN_H))
|
||||
cap_placed = cap.copy(); cap_placed.translate(Base.Vector(BTN_X, BTN_CY, H - CAP_SHAFT_H))
|
||||
|
||||
# 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))
|
||||
|
||||
# 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
|
||||
shelf_slab = box(BPCB_L + SHELF_WALL*2, BPCB_W + SHELF_WALL*2, shelf_h,
|
||||
shelf_ox - SHELF_WALL, shelf_oy - SHELF_WALL,
|
||||
PCB_BOT_Z - shelf_h)
|
||||
shelf_hole = box(BPCB_L, BPCB_W, shelf_h + 2.0,
|
||||
shelf_ox, shelf_oy, PCB_BOT_Z - shelf_h - 1.0)
|
||||
shelf = shelf_slab.cut(shelf_hole)
|
||||
if floor_top_shell < PCB_BOT_Z < H - WALL:
|
||||
top_shell = top_shell.fuse(shelf)
|
||||
|
||||
# 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 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)
|
||||
#
|
||||
# Geometry at origin:
|
||||
# Shaft: Z = 0 (bottom/inner) → Z = CAP_SHAFT_H = WALL (top/flush)
|
||||
# Rim: Z = -CAP_RIM_H → Z = 0 (hangs inside cavity)
|
||||
# Nubbin: Z = -CAP_RIM_H-NUBBIN_H → Z = -CAP_RIM_H
|
||||
#
|
||||
# Placed so shaft top = H → flush with top face.
|
||||
# ═════════════════════════════════════════════════════════════════════════════
|
||||
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)
|
||||
cap_placed = cap_raw.copy()
|
||||
cap_placed.translate(Base.Vector(BTN_X, BTN_CY, H - CAP_SHAFT_H))
|
||||
|
||||
# ═════════════════════════════════════════════════════════════════════════════
|
||||
# REGISTER OBJECTS
|
||||
# ═════════════════════════════════════════════════════════════════════════════
|
||||
bot_obj = doc.addObject("Part::Feature", "Shell_Bottom")
|
||||
bot_obj.Shape = bot_shell
|
||||
bot_obj.ViewObject.ShapeColor = (0.12, 0.12, 0.14)
|
||||
bot_obj.ViewObject.Transparency = 0
|
||||
|
||||
top_obj = doc.addObject("Part::Feature", "Shell_Top")
|
||||
top_obj.Shape = top_shell
|
||||
top_obj.ViewObject.ShapeColor = (0.20, 0.20, 0.26)
|
||||
top_obj.ViewObject.Transparency = 0
|
||||
|
||||
cap_obj = doc.addObject("Part::Feature", "Button_Cap")
|
||||
cap_obj.Shape = cap_placed
|
||||
cap_obj.ViewObject.ShapeColor = (0.80, 0.80, 0.86)
|
||||
cap_obj.ViewObject.Transparency = 0
|
||||
# ─── REGISTER ────────────────────────────────────────────────────────────────
|
||||
for name, shape, color in [("Shell_Bottom", bot_shell, (0.15, 0.15, 0.18)),
|
||||
("Shell_Top", top_shell, (0.25, 0.25, 0.32)),
|
||||
("Button_Cap", cap_placed, (0.7, 0.7, 0.7))]:
|
||||
obj = doc.addObject("Part::Feature", name)
|
||||
obj.Shape = shape
|
||||
obj.ViewObject.ShapeColor = color
|
||||
|
||||
doc.recompute()
|
||||
Gui.activeDocument().activeView().viewIsometric()
|
||||
Gui.SendMsgToActiveView("ViewFit")
|
||||
|
||||
# ═════════════════════════════════════════════════════════════════════════════
|
||||
# SUMMARY
|
||||
# ═════════════════════════════════════════════════════════════════════════════
|
||||
print("=" * 62)
|
||||
print("IMU Pointer v8")
|
||||
print("=" * 62)
|
||||
print(f"Body: {L:.0f} × {W:.0f} mm")
|
||||
print(f"Height: {H:.0f} mm uniform (no taper)")
|
||||
print(f"Wall: {WALL:.1f} mm CR = {CR:.1f} mm Edge fillet = {EDGE_FILLET:.1f} mm")
|
||||
print(f"Split Z: {SPLIT_Z:.1f} mm "
|
||||
f"(USB-C top = {USBC_Z + USBC_H:.1f} mm)")
|
||||
print(f"Top shell interior height: {top_cav_lz:.1f} mm (Z {SPLIT_Z:.1f} → {H - WALL:.1f})")
|
||||
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} (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)")
|
||||
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 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)
|
||||
Gui.SendMsgToActiveView("ViewFit")
|
||||
Reference in New Issue
Block a user