From 87fc2a3574a9a68379f7105c893dfc0c49aa1920 Mon Sep 17 00:00:00 2001 From: Nik Rozman Date: Thu, 19 Mar 2026 21:47:42 +0100 Subject: [PATCH] Update 3D model --- model/pointer.FCMacro | 618 ++++++++++++++++++++++++++---------------- 1 file changed, 379 insertions(+), 239 deletions(-) diff --git a/model/pointer.FCMacro b/model/pointer.FCMacro index 3736587..5530bbf 100644 --- a/model/pointer.FCMacro +++ b/model/pointer.FCMacro @@ -1,290 +1,430 @@ -# IMU Pointer Enclosure +""" +IMU Pointer Enclosure — v6 +============================ +Fixes from v5 (diagnosed from rendered images): + + 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. + + 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. + + 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. + +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. +""" import FreeCAD as App import FreeCADGui as Gui import Part +import math from FreeCAD import Base -doc = App.newDocument("pointer") +doc = App.newDocument("pointer_v7") -# Global dimensions -L = 115.0 -W = 36.0 -H = 20.0 -WALL = 3.5 -CR = 3.0 -TOL = 0.25 +# ───────────────────────────────────────────────────────────────────────────── +# 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 (+1 mm vs v6 — closes taper floor gap) +CR = 5.0 # corner fillet radius (vertical edges) +TOL = 0.25 # fit tolerance -# Rail and lid -RAIL_H = 4.5 -RAIL_D = 2.0 -LIP_H = 2.0 -LIP_OVER = 1.5 -LIP_EMBED = 0.2 +# 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_LEN = 100.0 # unused but kept to avoid NameError -LID_H = RAIL_H - LIP_H - TOL - 0.55 +# 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 -# Board dimensions -PCB_T = 1.0 -BRD_L = 21.0 -BRD_W = 17.5 -BRD_X = WALL -BRD_Y = (W - BRD_W) / 2 +# 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 +# Flex notch through tongue (for snap release) +NOTCH_W = 8.0 +NOTCH_H = TONGUE_H + 0.5 + +# ───────────────────────────────────────────────────────────────────────────── +# 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 +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 -# Clip arms -ARM_LEN = 5.0 -ARM_THICK = 1.6 -ARM_H = BRD_Z + PCB_T + 0.8 -CLIP_TOL = 0.35 +# ───────────────────────────────────────────────────────────────────────────── +# 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 -# USB-C cutout -USBC_W = 11.0 -USBC_H = 7.0 -USBC_Z = 4.5 +# ───────────────────────────────────────────────────────────────────────────── +# BUTTON +# ───────────────────────────────────────────────────────────────────────────── +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 +CAP_RIM_H = 1.5 +NUBBIN_R = 1.8 +NUBBIN_H = 2.0 -# Battery section -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 -BAT_CLIP_Y = 8.0 +# Switch geometry (adjust to match your Omron) +SWITCH_BODY_H = 5.0 +STEM_H = 2.5 +GAP = 0.5 -# Circular notch -NOTCH_R = (USBC_W + TOL) / 2 -NOTCH_DEPTH = WALL + 2.0 +# 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 +POST_OD = 4.0; POST_R = POST_OD / 2.0 +POST_ID = 1.9; POST_IR = POST_ID / 2.0 +POST_SEP = 3.0 -# Circular notch helper -def circular_notch(face_x, cy, cz, r, depth): - circle = Part.makeCircle(r, Base.Vector(face_x, cy, cz), Base.Vector(1, 0, 0)) - face = Part.Face(Part.Wire(circle)) - return face.extrude(Base.Vector(-depth, 0, 0)) +BPCB_L = 16.0 +BPCB_W = 16.0 +SHELF_WALL = 2.0 +# ───────────────────────────────────────────────────────────────────────────── +# 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: - vert = [e for e in b.Edges - if abs(e.Vertexes[0].Z - e.Vertexes[1].Z) > lz * 0.9] - if vert: - b = b.makeFillet(r, vert) - except Exception: - pass - return b - - -# Simple box helper -def box(lx, ly, lz, ox=0, oy=0, oz=0): +def box(lx, ly, lz, ox=0.0, oy=0.0, oz=0.0): return Part.makeBox(lx, ly, lz, Base.Vector(ox, oy, oz)) +def cyl(r, h, cx=0.0, cy=0.0, cz=0.0): + return Part.makeCylinder(r, h, Base.Vector(cx, cy, cz)) -# Rounded slot helper -def rounded_slot(depth, w, h, ox, oy, oz, r=None): - if r is None: - r = h / 2.0 +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)) - r = min(r, h / 2.0, w / 2.0) - - 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): +def fillet_vert(solid, r, min_len=4.0): + """Fillet edges that are primarily vertical (parallel to Z).""" + 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 +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)) - 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 +# ═════════════════════════════════════════════════════════════════════════════ +# BOTTOM SHELL (Z = 0 → SPLIT_Z, open on top) +# ═════════════════════════════════════════════════════════════════════════════ - platform = box( - plat_w, plat_w, - PLATFORM_H + PCB_T, - plat_x, plat_y, WALL - ) +# 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) - 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) +# 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 +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) + # 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) + 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}") + else: + print("Bottom shell: no horizontal edges found — skipped") +except Exception as exc: + print(f"Bottom shell horizontal fillet skipped: {exc}") - 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) +# No taper wedge — removed per user request - 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 +# 3. Inner cavity — floor at WALL, ceiling at SPLIT_Z (open top, no ceiling) +bot_cav_lx = L - WALL * 2 +bot_cav_ly = W - WALL * 2 +bot_cav_lz = SPLIT_Z - WALL # floor(WALL) → SPLIT_Z +bot_inner = box(bot_cav_lx, bot_cav_ly, bot_cav_lz, WALL, WALL, WALL) +bot_shell = bot_outer.cut(bot_inner) - corner_block = box( - corner_block_w, corner_block_w, ARM_H, - cb_ox, cb_oy, WALL - ) +# 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) - return platform.fuse(arm_x.fuse(arm_y).fuse(corner_block)) +# 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)) +bot_shell = bot_shell.fuse(tongue) - -# Base outer body -base = rbox(L, W, H) - -# Inner cavity -base = base.cut( - box(L - WALL * 2, W - WALL * 2, H - WALL, - WALL, WALL, WALL) -) - -rail_z = H - RAIL_H -groove_h = RAIL_H - LIP_H - -# Rail grooves -base = base.cut( - box(L - WALL * 2, RAIL_D, groove_h, - WALL, WALL - RAIL_D, rail_z) -) - -base = base.cut( - 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), +# 5. 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)) -for cx, cy, ix, iy in clip_corners: - base = base.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 +bot_shell = bot_shell.cut( + rounded_slot(WALL * 6, USBC_W, USBC_H, + -WALL * 3, + W / 2.0 - USBC_W / 2.0, + USBC_Z)) -# USB-C opening -base = base.cut( - rounded_slot( - WALL * 3, - USBC_W, - USBC_H, - -WALL, - W / 2 - USBC_W / 2, - USBC_Z - ) -) +# 7. 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)) +bot_shell = bot_shell.fuse(box(2.0, BAT_CLIP_Y, BAT_H * 0.55, BAT_X + BAT_L, cy0, WALL)) -# Battery recess -base = base.cut( - box(BAT_L, BAT_W, 3.0, - BAT_X, BAT_Y, WALL) -) +# ═════════════════════════════════════════════════════════════════════════════ +# TOP SHELL (Z = SPLIT_Z → H, open on bottom, closed ceiling at H) +# ═════════════════════════════════════════════════════════════════════════════ +top_h = H - SPLIT_Z # = 7.5 mm -clip_y_start = BAT_Y + BAT_W / 2 - BAT_CLIP_Y / 2 +# 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) -base = base.fuse( - box(2.0, BAT_CLIP_Y, BAT_H * 0.55, - BAT_X - 2.0, clip_y_start, WALL) -) +# 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. +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) + # 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) + 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}") -base = base.fuse( - box(2.0, BAT_CLIP_Y, BAT_H * 0.55, - BAT_X + BAT_L, clip_y_start, WALL) -) +# 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 +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_inner = box(top_cav_lx, top_cav_ly, top_cav_lz, + WALL, WALL, SPLIT_Z) # starts exactly at SPLIT_Z +top_shell = top_outer.cut(top_inner) -# Circular notch in back wall - centred on base -notch_cz = rail_z + LID_H -base = base.cut(circular_notch(L, W / 2, notch_cz, NOTCH_R, NOTCH_DEPTH)) +# 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). +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) -# Lid -TAB_W = RAIL_D - TOL + 0.5 -LID_L = L - WALL * 2 - TOL -LID_EXTRA_TOL = 0.5 +# 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. +top_shell = top_shell.cut( + cyl(BTN_HOLE_R, H - SPLIT_Z + 2, BTN_X, BTN_CY, SPLIT_Z)) -LID_W = ( - W - WALL * 2 - - (TOL + LID_EXTRA_TOL) * 2 - + TAB_W * 2 -) +# 5. 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) -lid_y0 = WALL + TOL + LID_EXTRA_TOL - TAB_W -lid = box(LID_L, LID_W, LID_H, 0, lid_y0, 0) +# 6. Screw posts on top-shell floor +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) -lid.translate(Base.Vector(WALL + TOL, 0, rail_z)) +# ═════════════════════════════════════════════════════════════════════════════ +# 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. +# 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)) -# Final objects -base_obj = doc.addObject("Part::Feature", "Pointer_Base") -base_obj.Shape = base -base_obj.ViewObject.ShapeColor = (0.12, 0.12, 0.14) +# ═════════════════════════════════════════════════════════════════════════════ +# 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 -lid_obj = doc.addObject("Part::Feature", "Pointer_Lid") -lid_obj.Shape = lid -lid_obj.ViewObject.ShapeColor = (0.28, 0.28, 0.34) -lid_obj.ViewObject.Transparency = 25 +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 doc.recompute() Gui.activeDocument().activeView().viewIsometric() -Gui.SendMsgToActiveView("ViewFit") \ No newline at end of file +Gui.SendMsgToActiveView("ViewFit") + +# ═════════════════════════════════════════════════════════════════════════════ +# SUMMARY +# ═════════════════════════════════════════════════════════════════════════════ +print("=" * 62) +print("IMU Pointer v7") +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() +print(f"Button hole: ⌀{BTN_HOLE_R*2:.0f} mm X={BTN_X} Y={BTN_CY:.0f}") +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() +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() +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