air-mouse/model/pointer.FCMacro

# IMU Pointer Enclosure

import FreeCAD as App
import FreeCADGui as Gui
import Part
from FreeCAD import Base

doc = App.newDocument("pointer")

# Global dimensions
L = 115.0
W = 36.0
H = 20.0
WALL = 3.5
CR = 3.0
TOL = 0.25

# Rail and lid
RAIL_H = 4.5
RAIL_D = 2.0
LIP_H = 2.0
LIP_OVER = 1.5
LIP_EMBED = 0.2

LID_H = RAIL_H - LIP_H - TOL - 0.55

# Board dimensions
PCB_T = 1.0
BRD_L = 21.0
BRD_W = 17.5
BRD_X = WALL
BRD_Y = (W - BRD_W) / 2

PLATFORM_H = 0.5
BRD_Z = WALL + PLATFORM_H

# Clip arms
ARM_LEN = 5.0
ARM_THICK = 1.6
ARM_H = BRD_Z + PCB_T + 0.8
CLIP_TOL = 0.35

# USB-C cutout
USBC_W = 11.0
USBC_H = 7.0
USBC_Z = 4.5

# Battery section
BAT_L = 50.0
BAT_W = 12.0
BAT_H = 12.0
BAT_X = BRD_X + BRD_L + 8.0
BAT_Y = (W - BAT_W) / 2
BAT_CLIP_Y = 8.0


# 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):
    return Part.makeBox(lx, ly, lz, Base.Vector(ox, oy, oz))


# Rounded slot helper
def rounded_slot(depth, w, h, ox, oy, oz, r=None):
    if r is None:
        r = h / 2.0

    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):

    plat_w = ARM_THICK + CLIP_TOL

    plat_x = corner_x if inward_x > 0 else corner_x - plat_w
    plat_y = corner_y if inward_y > 0 else corner_y - plat_w

    platform = box(
        plat_w, plat_w,
        PLATFORM_H + PCB_T,
        plat_x, plat_y, WALL
    )

    ax_ox = corner_x if inward_x > 0 else corner_x - ARM_LEN
    ax_oy = corner_y - ARM_THICK - CLIP_TOL if inward_y > 0 else corner_y + CLIP_TOL
    arm_x = box(ARM_LEN, ARM_THICK, ARM_H, ax_ox, ax_oy, WALL)

    ay_oy = corner_y if inward_y > 0 else corner_y - ARM_LEN
    ay_ox = corner_x - ARM_THICK - CLIP_TOL if inward_x > 0 else corner_x + CLIP_TOL
    arm_y = box(ARM_THICK, ARM_LEN, ARM_H, ay_ox, ay_oy, WALL)

    corner_block_w = ARM_THICK + CLIP_TOL
    cb_ox = corner_x - corner_block_w if inward_x > 0 else corner_x
    cb_oy = corner_y - corner_block_w if inward_y > 0 else corner_y

    corner_block = box(
        corner_block_w, corner_block_w, ARM_H,
        cb_ox, cb_oy, WALL
    )

    return platform.fuse(arm_x.fuse(arm_y).fuse(corner_block))


# Base outer body
base = rbox(L, W, H)

# 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),
    (BRD_X + BRD_L, BRD_Y + BRD_W, -1, -1),
]

for cx, cy, ix, iy in clip_corners:
    base = base.fuse(make_clip(cx, cy, ix, iy))

# USB-C opening
base = base.cut(
    rounded_slot(
        WALL * 3,
        USBC_W,
        USBC_H,
        -WALL,
        W / 2 - USBC_W / 2,
        USBC_Z
    )
)

# Battery recess
base = base.cut(
    box(BAT_L, BAT_W, 3.0,
        BAT_X, BAT_Y, WALL)
)

clip_y_start = BAT_Y + BAT_W / 2 - BAT_CLIP_Y / 2

base = base.fuse(
    box(2.0, BAT_CLIP_Y, BAT_H * 0.55,
        BAT_X - 2.0, clip_y_start, WALL)
)

base = base.fuse(
    box(2.0, BAT_CLIP_Y, BAT_H * 0.55,
        BAT_X + BAT_L, clip_y_start, WALL)
)

# Lid
TAB_W = RAIL_D - TOL + 0.5
LID_L = L - WALL * 2 - TOL
LID_EXTRA_TOL = 0.5

LID_W = (
    W - WALL * 2
    - (TOL + LID_EXTRA_TOL) * 2
    + TAB_W * 2
)

lid_y0 = WALL + TOL + LID_EXTRA_TOL - TAB_W

lid = box(LID_L, LID_W, LID_H, 0, lid_y0, 0)

lid = lid.cut(
    box(WALL * 2, USBC_W + TOL, LID_H + 0.2,
        LID_L - WALL,
        W / 2 - (USBC_W + TOL) / 2,
        -0.1)
)

lid.translate(Base.Vector(WALL + TOL, 0, rail_z))

# Final objects
base_obj = doc.addObject("Part::Feature", "Pointer_Base")
base_obj.Shape = base
base_obj.ViewObject.ShapeColor = (0.12, 0.12, 0.14)

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

doc.recompute()
Gui.activeDocument().activeView().viewIsometric()
Gui.SendMsgToActiveView("ViewFit")