Add channels for wires embedded in the lids.

bike-lights/case/bike-light-enclosure.scad

@@ -0,0 +1,174 @@
+width = 65;
+length = 75;
+height = 16;
+wall_thickness = 2;
+guide_thickness = 1;
+power_width = 21;
+output_width = 37.5;
+half_wall_thickness = wall_thickness / 2;
+standoff_thickness = 10;
+hole_diameter = 3;
+// The radius of a nut in mm. However, based on my measurements, I'm not actually sure I have this right. The short height of a nut is 7.86mm. Derive from there.
+nut_radius = 8.5 * cos(30) / 2;
+nut_height = 2.69; // mm
+screw_radius = 2;
+handlebar_radius = 15;
+clasp_thickness = 4;
+clasp_width = 35;
+circular_face_count = 48;
+
+module hexagon(r, h) {
+    pi = 3.1415926;
+    polyhedron(
+        points=[
+            [r, 0, 0],
+            [r * cos(60), r * sin(60), 0],
+            [r * cos(120), r * sin(120), 0],
+            [r * cos(180), r * sin(180), 0],
+            [r * cos(240), r * sin(240), 0],
+            [r * cos(300), r * sin(300), 0],
+
+            [r, 0, h],
+            [r * cos(60), r * sin(60), h],
+            [r * cos(120), r * sin(120), h],
+            [r * cos(180), r * sin(180), h],
+            [r * cos(240), r * sin(240), h],
+            [r * cos(300), r * sin(300), h],
+        ],
+        faces=[
+            [0, 1, 2, 3, 4, 5],
+            [11, 10, 9, 8, 7, 6],
+            [6, 7, 1, 0],
+            [7, 8, 2, 1],
+            [8, 9, 3, 2],
+            [9, 10, 4, 3],
+            [10, 11, 5, 4],
+            [11, 6, 0, 5],
+        ]
+    );
+}
+
+// Nut holders are blocks that have a hole drilled through them and a hexagonal-shaped cavity. The idea is to 
+module nut_holder() {
+    difference() {
+        translate([-4.5, -4.5, -2]) cube([9, 9, 4]);
+        union() {
+            translate([0, 0, -1]) hexagon(nut_radius, 2);
+            cylinder(h = 6, r = screw_radius, center = true, $fn = 24);
+        }
+    }
+}
+
+module screw_hole() {
+    union() {
+        translate([0, 0, 4]) cylinder(h = 2.1, r = screw_radius * 2, center = true, $fn = 24);
+        cylinder(h = 6, r = screw_radius, center = true, $fn = 24);
+    }
+}
+
+module base() {
+    cube([width, length, wall_thickness]);
+}
+
+module face() {
+    union() {
+        cube([width, length, wall_thickness / 2]);
+        translate([wall_thickness, wall_thickness, wall_thickness / 2]) cube([width-wall_thickness*2, length-wall_thickness*2, wall_thickness / 2]);
+        translate([4.5 + wall_thickness, 4.5 + wall_thickness, 4]) nut_holder();
+        translate([width - 4.5 - wall_thickness, 4.5 + wall_thickness, 4]) nut_holder();
+        translate([width - 4.5 - wall_thickness, length - 4.5 - wall_thickness, 4]) nut_holder();
+        translate([4.5 + wall_thickness, length - 4.5 - wall_thickness, 4]) nut_holder();
+    }
+}
+
+module wall(length) {
+    cube([length, height, wall_thickness]);
+}
+
+module power_wall() {
+    difference() {
+        wall(65);
+        translate([9, 2, -.5]) cube([power_width, height, wall_thickness + 1]);
+    }
+}
+
+module output_wall() {
+    difference() {
+        wall(65);
+        translate([9, 2, -.5]) cube([output_width, height, wall_thickness + 1]);
+    }
+}
+
+// Use hexagons as cutouts into which I can install a hex nut. This isn't quite right yet, but close.
+// hexagon(nut_radius, 1);
+
+// cube([standoff_thickness, standoff_thickness, 2]);
+
+/*
+difference() {
+    union() {
+        base();
+        rotate([90, 0, 90]) wall(75);
+        // translate([width - wall_thickness, 0, 0]) rotate([90, 0, 90]) wall(length);
+        // rotate([90, 0, 0]) power_wall();
+        // translate([0, length, 0]) rotate([90, 0, 0]) output_wall();
+        // translate([wall_thickness,
+        //            wall_thickness,
+        //            wall_thickness]) standoff();
+        // translate([width - wall_thickness - standoff_thickness,
+        //            wall_thickness,
+        //            wall_thickness]) standoff();
+        // translate([wall_thickness,
+        //            length - wall_thickness - standoff_thickness,
+        //            wall_thickness]) standoff();
+        // translate([width - wall_thickness - standoff_thickness,
+        //            length - wall_thickness - standoff_thickness,
+        //            wall_thickness]) standoff();
+    }
+    // translate([-half_wall_thickness, -wall_thickness - half_wall_thickness, height - half_wall_thickness]) cube([wall_thickness, length + wall_thickness * 2, wall_thickness]);
+    // translate([width - half_wall_thickness, -wall_thickness - half_wall_thickness, height - half_wall_thickness]) cube([wall_thickness, length + wall_thickness * 2, wall_thickness]);
+    // translate([-half_wall_thickness, -half_wall_thickness, height - half_wall_thickness]) rotate([0, 0, 270]) cube([wall_thickness, width + wall_thickness * 2, wall_thickness]);
+    // translate([-half_wall_thickness, length + half_wall_thickness, height - half_wall_thickness]) rotate([0, 0, 270]) cube([wall_thickness, width + wall_thickness * 2, wall_thickness]);
+}
+*/
+
+module box() {
+    difference() {
+        union() {
+            cube([width, length, wall_thickness * 2]);
+            translate([0, 0, wall_thickness]) rotate([90, 0, 90]) wall(length);
+            translate([width - wall_thickness, 0, wall_thickness]) rotate([90, 0, 90]) wall(length);
+            translate([0, wall_thickness, wall_thickness]) rotate([90, 0, 0]) wall(width);
+            translate([0, length, wall_thickness]) rotate([90, 0, 0]) wall(width);
+        }
+        translate([4.5 + wall_thickness, 4.5 + wall_thickness, 4]) rotate([180, 0, 0]) screw_hole();
+        translate([width - 4.5 - wall_thickness, 4.5 + wall_thickness, 4]) rotate([180, 0, 0]) screw_hole();
+        translate([width - 4.5 - wall_thickness, length - 4.5 - wall_thickness, 4]) rotate([180, 0, 0]) screw_hole();
+        translate([4.5 + wall_thickness, length - 4.5 - wall_thickness, 4]) rotate([180, 0, 0]) screw_hole();
+    }
+}
+
+module top_clasp() {
+    difference() {
+        union() {
+            cylinder(h = clasp_width, r = handlebar_radius + clasp_thickness, center = true, $fn = circular_face_count);
+            translate([0, 0, -clasp_width / 2]) cylinder(h = 1, r = handlebar_radius + clasp_thickness + 1, center = true, $fn = circular_face_count);
+            translate([0, 0, -clasp_width / 2 + 4]) cylinder(h = 1, r = handlebar_radius + clasp_thickness + 1, center = true, $fn = circular_face_count);
+            translate([0, 0, clasp_width / 2]) cylinder(h = 1, r = handlebar_radius + clasp_thickness + 1, center = true, $fn = circular_face_count);
+            translate([0, 0, clasp_width / 2 - 4]) cylinder(h = 1, r = handlebar_radius + clasp_thickness + 1, center = true, $fn = circular_face_count);
+            translate([-handlebar_radius-5, -10, -clasp_width / 2 + 6]) cube([6, 20, clasp_width - 12]);
+        }
+        translate([-0.5, 0, 0]) cylinder(h = clasp_width+2, r = handlebar_radius + 1, center = true, $fn = circular_face_count);
+        translate([-0.5, -handlebar_radius - 10, -clasp_width / 2 - 1]) cube([handlebar_radius + 10, handlebar_radius * 2 + 20, clasp_width + 2]);
+    }
+}
+
+module body() {
+    union() {
+        box();
+        translate([width / 2, length / 2, -5 - handlebar_radius]) rotate([0, 90, 90]) top_clasp();
+    }
+}
+
+body();
+translate([width + 10, 0, 0]) face();

bike-lights/case/clasp.scad

@@ -0,0 +1,21 @@
+handlebar_radius = 15;
+clasp_thickness = 4;
+circular_face_count = 48;
+clasp_width = 35;
+
+module top_clasp() {
+    difference() {
+        union() {
+            cylinder(h = clasp_width, r = handlebar_radius + clasp_thickness, center = true, $fn = circular_face_count);
+            translate([0, 0, -clasp_width / 2]) cylinder(h = 1, r = handlebar_radius + clasp_thickness + 1, center = true, $fn = circular_face_count);
+            translate([0, 0, -clasp_width / 2 + 4]) cylinder(h = 1, r = handlebar_radius + clasp_thickness + 1, center = true, $fn = circular_face_count);
+            translate([0, 0, clasp_width / 2]) cylinder(h = 1, r = handlebar_radius + clasp_thickness + 1, center = true, $fn = circular_face_count);
+            translate([0, 0, clasp_width / 2 - 4]) cylinder(h = 1, r = handlebar_radius + clasp_thickness + 1, center = true, $fn = circular_face_count);
+            translate([-handlebar_radius-5, -10, -clasp_width / 2 + 6]) cube([6, 20, clasp_width - 12]);
+        }
+        translate([-0.5, 0, 0]) cylinder(h = clasp_width+2, r = handlebar_radius + 1, center = true, $fn = circular_face_count);
+        translate([-0.5, -handlebar_radius - 10, -clasp_width / 2 - 1]) cube([handlebar_radius + 10, handlebar_radius * 2 + 20, clasp_width + 2]);
+    }
+}
+
+top_clasp();

bike-lights/case/common.scad

@@ -1,3 +1,8 @@
+
+module hexagon(r, h) {
+    cylinder(r = r, h = h, center = 2, $fn = 6);
+}
+
 module pill(length, bevel) {
     hull() {
         translate([0, 0, (-length / 2) + bevel]) sphere(r = bevel);
@@ -5,6 +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];
@@ -48,6 +74,7 @@ module box(length, width, height, bevel = 0) {
             rotate([90, 0, 0])
             rotate([0, 90, 0])
             box_face([width, height, wall_thickness], bevel);
+
         translate([length - wall_thickness + bevel, 0, bevel])
             rotate([90, 0, 0])
             rotate([0, 90, 0])
@@ -55,3 +82,11 @@ module box(length, width, height, bevel = 0) {
     }
 }
 
+module box_side_slider(length, width, height) {
+    difference() {
+        box_face([width - wall_thickness * 2 + 4, height, wall_thickness], bevel);
+        translate([-1, -1, 1]) cube([4-threshold, height+2, 4-threshold]);
+        color("red") translate([width - wall_thickness * 2 + 1, -1, 1]) cube([4-threshold, height+2, 4-threshold]);
+    }
+}
+

bike-lights/case/control_panel.scad

@@ -4,7 +4,7 @@ threshold = 0.1;
 board_length = 92;
 board_width = 72;
 board_height = 21.5;
-wall_thickness = 2;
+wall_thickness = 4;
 bevel = 0.5;
 
 hinge_radius = 2.5;
@@ -13,16 +13,63 @@ case_width = board_width + wall_thickness * 2;
 case_length = board_length + wall_thickness * 2;
 case_height = board_height + wall_thickness;
 
+handlebar_radius = 15;
+clasp_thickness = 4;
+circular_face_count = 48;
+clasp_width = 35;
+
 include <./common.scad>;
 
+module top_clasp() {
+    difference() {
+        union() {
+            cylinder(h = clasp_width, r = handlebar_radius + clasp_thickness, center = true, $fn = circular_face_count);
+            translate([0, 0, -clasp_width / 2]) cylinder(h = 1, r = handlebar_radius + clasp_thickness + 1, center = true, $fn = circular_face_count);
+            translate([0, 0, -clasp_width / 2 + 4]) cylinder(h = 1, r = handlebar_radius + clasp_thickness + 1, center = true, $fn = circular_face_count);
+            translate([0, 0, clasp_width / 2]) cylinder(h = 1, r = handlebar_radius + clasp_thickness + 1, center = true, $fn = circular_face_count);
+            translate([0, 0, clasp_width / 2 - 4]) cylinder(h = 1, r = handlebar_radius + clasp_thickness + 1, center = true, $fn = circular_face_count);
+            translate([-handlebar_radius-5, -10, -clasp_width / 2 + 6]) cube([6, 20, clasp_width - 12]);
+        }
+        translate([-0.5, 0, 0]) cylinder(h = clasp_width+2, r = handlebar_radius + 1, center = true, $fn = circular_face_count);
+        translate([-0.5, -handlebar_radius - 10, -clasp_width / 2 - 1]) cube([handlebar_radius + 10, handlebar_radius * 2 + 20, clasp_width + 2]);
+    }
+}
+
 module hinge(length) {
     difference() {
         union() {
-            cylinder(h = length, r = hinge_radius);
-            translate([0, -hinge_radius, 0])
-                cube([hinge_radius, hinge_radius * 2, length]);
+            cube([hinge_radius * 2, length, hinge_radius], center = true);
+            translate([0, 0, -1.5]) rotate([90, 0, 0]) cylinder(h = length, r = hinge_radius, center = true);
         }
-        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);
+    }
+}
+
+module base_case(length, width, height, bevel = 0) {
+    difference() {
+        union() {
+            channel(length + wall_thickness / 2, width, height, bevel);
+
+            translate([-bevel, 0, bevel])
+                rotate([90, 0, 0])
+                rotate([0, 90, 0])
+                box_face([width, height, wall_thickness], bevel);
+
+            // These are the sleds at the bottom of the case that should hold the lower of the two boards down
+            color("blue") translate([0, wall_thickness - 2, wall_thickness + 4]) cube([length - 8, 4, wall_thickness / 2]);
+            color("blue") translate([wall_thickness - 2, wall_thickness - 4, wall_thickness + 4]) cube([4, width, wall_thickness / 2]);
+            color("blue") translate([length - 25, width - wall_thickness * 3 / 2, wall_thickness + 6]) cube([16, wall_thickness, wall_thickness / 2]);
+        }
+
+        // This makes an indent at the bottom to accomodate solder joins
+        translate([wall_thickness + 2, wall_thickness + 2, wall_thickness / 2]) cube([length, width - wall_thickness * 2 - 4, wall_thickness / 2 + threshold]);
+
+        // This creates a cutout that lets the power plug slide in better.
+        translate([wall_thickness, width - wall_thickness, wall_thickness]) cube([length, 2, 6]);
+
+        // These two put in the slots that should allow the fourth wall to be slotted into place.
+        color("red") translate([length - 1, wall_thickness - 2, 4]) cube([2, 2, height]);
+        color("red") translate([length - 1, width - wall_thickness, 4]) cube([2, 2, height]);
     }
 }
 
@@ -33,11 +80,16 @@ module main_case() {
 
     difference() {
         union() {
-            box(case_length,
+            base_case(case_length,
                 case_width,
                 case_height,
                 bevel);
 
+            translate([-bevel, 0, bevel])
+                rotate([90, 0, 0])
+                rotate([0, 90, 0])
+                box_face([case_width, case_height, wall_thickness], bevel);
+
             translate([0, -hinge_radius - bevel + threshold, hinge_z_offset + bevel])
                 rotate([90, 0, 0])
                 rotate([0, 90, 0])
@@ -65,31 +117,94 @@ module main_case() {
                 rotate([0, 180, 0])
                 linear_extrude(1)
                 text("right", size = 3);
+            // translate([case_length / 2, case_width / 2, -20]) rotate([0, 90, 0]) top_clasp();
         }
 
-        color("green", 1) translate([8.5 + wall_thickness, case_width - wall_thickness - threshold, wall_thickness])
-            cube([60, wall_thickness * 2, 7]);
+        translate([case_length / 2, case_width / 2, -threshold]) hexagon(4.5, 6);
+
+        # translate([8.5 + wall_thickness, case_width - wall_thickness - threshold, wall_thickness])
+        # 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])
-                cube([60, 16, wall_thickness + threshold]);
+            translate([0, lid_width / 5, 0.4]) lamp();
+            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])
-            rotate([180, 0, 0])
-            rotate([0, 90, 0]) hinge(case_length / 2 - 2);
+        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);
+        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);
+
+        translate([0, -lid_width / 2 + bevel, -3]) rounded_cube([20, wall_thickness / 2, 10], bevel);
+        color("blue") translate([-9, -lid_width / 2 + 1.5, -6]) rotate([90, 0, 0]) rotate([0, 90, 0]) linear_extrude(18) circle(1, $fn = 3);
+        color("blue") translate([-9, -lid_width / 2 + 1.5, -7]) rotate([90, 0, 0]) rotate([0, 90, 0]) linear_extrude(18) circle(1, $fn = 3);
+    }
+}
+
+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);
     }
 }
 
-// main_case();
-// color("red", 1) translate([0, 0, case_height + wall_thickness / 2]) lid();
-// color("red", 1) translate([0, 0, 40]) lid();

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();
 

bike-lights/case/control_panel_slider.scad

@@ -0,0 +1,4 @@
+
+include <./control_panel.scad>
+
+box_side();