Work out a lid that contains integrated lights and buttons

bike-lights/case/common.scad

@@ -1,6 +1,6 @@
 
 module hexagon(r, h) {
-    cylinder(r = r, h = h, $fn = 6);
+    cylinder(r = r, h = h, center = 2, $fn = 6);
 }
 
 module pill(length, bevel) {
@@ -10,6 +10,27 @@ module pill(length, bevel) {
     }
 }
 
+module rounded_cube(dimensions, bevel = 0) {
+    x = dimensions[0];
+    y = dimensions[1];
+    z = dimensions[2];
+
+    if (bevel > 0) {
+        hull() {
+            translate([-x / 2 + bevel, -y / 2 + bevel, -z / 2 + bevel]) sphere(r = bevel);
+            translate([ x / 2 - bevel, -y / 2 + bevel, -z / 2 + bevel]) sphere(r = bevel);
+            translate([ x / 2 - bevel,  y / 2 - bevel, -z / 2 + bevel]) sphere(r = bevel);
+            translate([-x / 2 + bevel,  y / 2 - bevel, -z / 2 + bevel]) sphere(r = bevel);
+            translate([-x / 2 + bevel, -y / 2 + bevel,  z / 2 - bevel]) sphere(r = bevel);
+            translate([ x / 2 - bevel, -y / 2 + bevel,  z / 2 - bevel]) sphere(r = bevel);
+            translate([ x / 2 - bevel,  y / 2 - bevel,  z / 2 - bevel]) sphere(r = bevel);
+            translate([-x / 2 + bevel,  y / 2 - bevel,  z / 2 - bevel]) sphere(r = bevel);
+        }
+    } else {
+        cube(dimensions, center = true);
+    }
+}
+
 module box_face(dimensions, bevel = 0) {
     x = dimensions[0];
     y = dimensions[1];

bike-lights/case/control_panel.scad

@@ -38,11 +38,10 @@ module top_clasp() {
 module hinge(length) {
     difference() {
         union() {
-            cylinder(h = length, r = hinge_radius);
+            cube([hinge_radius * 2, length, hinge_radius], center = true);
-            translate([0, -hinge_radius, 0])
+            translate([0, 0, -1.5]) rotate([90, 0, 0]) cylinder(h = length, r = hinge_radius, center = true);
-                cube([hinge_radius, hinge_radius * 2, length]);
         }
-        translate([0, 0, -threshold / 2]) cylinder(h = length + threshold, r = 1);
+        translate([0, threshold / 2, -1.5]) rotate([90, 0, 0]) cylinder(h = length + threshold * 2, r = 1, center = true);
     }
 }
 
@@ -123,29 +122,85 @@ module main_case() {
 
         translate([case_length / 2, case_width / 2, -threshold]) hexagon(4.5, 6);
 
-        color("green", 1) translate([8.5 + wall_thickness, case_width - wall_thickness - threshold, wall_thickness])
+        # translate([8.5 + wall_thickness, case_width - wall_thickness - threshold, wall_thickness])
-            cube([60, wall_thickness * 2, 7]);
+        # cube([60, wall_thickness * 2, 7]);
+    }
+}
+
+module lamp() {
+    union() {
+        translate([0, 0, -0.5]) cube([12.9 + threshold, 8, 4], center = true);
+        translate([0, 0, .88]) cube([5 + threshold, 5 + threshold, 1.56], center = true);
+        /*
+        translate([0, 0, -1.56]) cube([12.9, 7.6, wall_thickness], center = true);
+        */
+    }
+}
+
+module button() {
+    union() {
+        cube([3.5 + threshold, 6.1 + threshold, 4 + threshold], center = true);
+        translate([0, 0, -0.5]) cube([1.2, 7, 3 + threshold], center = true);
     }
 }
 
 module lid() {
     lid_width = case_width + hinge_radius * 2 + wall_thickness;
+    hinge_length = case_length / 4;
     union() {
         difference() {
-            box_face([case_length,
+            rounded_cube([case_length,
                       lid_width,
                       wall_thickness],
                      bevel);
-            translate([(case_length - 60) / 2, 14 + hinge_radius * 2, -threshold / 2])
+            translate([0, lid_width / 5, 0.4]) lamp();
-                cube([60, 16, wall_thickness + threshold]);
+            translate([-15, lid_width / 5, 0.4]) lamp();
+            translate([15, lid_width / 5, 0.4]) lamp();
+            translate([-30, lid_width / 5, 0]) button();
+            translate([30, lid_width / 5, 0]) button();
+
+            translate([0, lid_width / 5, -2]) cube([20, 7, 3], center = true);
+
+            color("black") translate([-2, lid_width / 5 - 5, -2]) rotate([0, 0, 90]) rotate([0, 90, 0]) cylinder(h=5, r = 1, center = true, $fn = circular_face_count);
+            color("black") translate([-17, lid_width / 5 - 5, -2]) rotate([0, 0, 90]) rotate([0, 90, 0]) cylinder(h=5, r = 1, center = true, $fn = circular_face_count);
+            color("black") translate([13, lid_width / 5 - 5, -2]) rotate([0, 0, 90]) rotate([0, 90, 0]) cylinder(h=5, r = 1, center = true, $fn = circular_face_count);
+            color("black") translate([-30, lid_width / 5 - 5, -2]) rotate([0, 0, 90]) rotate([0, 90, 0]) cylinder(h=5, r = 1, center = true, $fn = circular_face_count);
+            color("black") translate([30, lid_width / 5 - 5, -2]) rotate([0, 0, 90]) rotate([0, 90, 0]) cylinder(h=5, r = 1, center = true, $fn = circular_face_count);
+            color("black") translate([0, 10, -2]) rotate([0, 90, 0]) cylinder(h = 62, r = 1, center = true, $fn = circular_face_count);
+
+            color("red") translate([-33, 21, -2]) rotate([0, 90, 0]) cylinder(h = 5, r = 1, center = true, $fn = circular_face_count);
+            color("red") translate([-35, 13, -2]) rotate([0, 0, 90]) rotate([0, 90, 0]) cylinder(h = 18, r = 1, center = true, $fn = circular_face_count);
+            color("red") translate([33, 21, -2]) rotate([0, 90, 0]) cylinder(h = 5, r = 1, center = true, $fn = circular_face_count);
+            color("red") translate([35, 13, -2]) rotate([0, 0, 90]) rotate([0, 90, 0]) cylinder(h = 18, r = 1, center = true, $fn = circular_face_count);
+            color("red") translate([0, 5, -2]) rotate([0, 90, 0]) cylinder(h = 70, r = 1, center = true, $fn = circular_face_count);
         }
 
-        translate([case_length / 4 + 1, hinge_radius - 0.4, -hinge_radius])
+        translate([case_length / 2 - hinge_length / 2, lid_width / 2 - wall_thickness / 2 - 0.5, -wall_thickness / 2]) rotate([0, 0, 90]) hinge(hinge_length);
-            rotate([180, 0, 0])
+        translate([-case_length / 2 + hinge_length / 2, lid_width / 2 - wall_thickness / 2 - 0.5, -wall_thickness / 2]) rotate([0, 0, 90]) hinge(hinge_length);
-            rotate([0, 90, 0]) hinge(case_length / 2 - 2);
     }
 }
 
 module box_side() {
     box_side_slider(case_length, case_width, case_height);
 }
+
+module case_base() {
+    difference() {
+        rounded_cube([case_length, case_width, wall_thickness + 2], bevel = 0.5);
+        translate([wall_thickness, 0, 2]) rounded_cube([case_length + threshold, board_width + threshold, 2 + threshold]);
+
+        // These give a screw-hole in the center which will allow the clamp to be attached
+        translate([0, 0, -1]) hexagon(4.5, 2);
+        translate([0, 0, -wall_thickness / 2]) cylinder(r = 2, h = wall_thickness + threshold, center = true);
+
+        // and now a bit of an indentation to help the clip remain in place
+        translate([0, 0, -4.5]) cube([clasp_width + threshold, clasp_width + threshold, wall_thickness], center = true);
+
+        // here are some grooves along the edges that can be used to piece parts together
+        translate([wall_thickness / 2, case_width / 2 - wall_thickness / 2, wall_thickness / 2])
+            cube([board_length + wall_thickness, wall_thickness / 2, wall_thickness / 2 + threshold], center = true);
+        translate([wall_thickness / 2, -case_width / 2 + wall_thickness / 2, wall_thickness / 2])
+            cube([board_length + wall_thickness, wall_thickness / 2, wall_thickness / 2 + threshold], center = true);
+    }
+}
+

bike-lights/case/control_panel_case.scad

@@ -1,4 +1,11 @@
 
 include <./control_panel.scad>
 
-main_case();
+/*
+difference() {
+    color("blue") rounded_cube([5, 5, 5], bevel = 0.5);
+    translate([0, 0, 1]) rounded_cube([4, 4, 4]);
+};
+*/
+
+case_base();

bike-lights/case/control_panel_lid.scad

@@ -2,4 +2,5 @@
 include <./control_panel.scad>
 
 lid();
+// lamp();