bike-lights/case/enclosure.scad

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+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 = 96;
+
+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 + 1.5, center = true, $fn = circular_face_count);
+            translate([0, 0, -clasp_width / 2 + 4]) cylinder(h = 1, r = handlebar_radius + clasp_thickness + 1.5, center = true, $fn = circular_face_count);
+            translate([0, 0, clasp_width / 2]) cylinder(h = 1, r = handlebar_radius + clasp_thickness + 1.5, center = true, $fn = circular_face_count);
+            translate([0, 0, clasp_width / 2 - 4]) cylinder(h = 1, r = handlebar_radius + clasp_thickness + 1.5, 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();