housing: Adjust board fit

[tattlekey] / housing / tattlekey.scad

use <cherryVoid.scad>

key_interface_size = 18;
key_interface_corner_r = 5;
key_interface_thickness = 1.484;

// Chosen to let board fit inside
housing_inner_h = 8;
housing_inner_w = 21;

thickness = 1.7;

board_gap = 0.125;

wiring_l = 12;
extra_flare = wiring_l;

pico_board_l = 51.0;
pico_board_w = 21.0;
pico_total_h = 3.7;

$fs = .1;
$fa = 3;

slop = 128;
epsilon = 1/64;

module pico_hole(d, x, y) {
    translate([x, y, -slop/2])
    cylinder(h=slop, d = d);
}

module pico_board(gap = 0) {
    board_h = 1.0;
    translate([-gap, -gap, -gap])
    cube([pico_board_l + 2*gap, pico_board_w + 2*gap, board_h + 2*gap]);
}

module pico_w(hole_d = 2.1) {
    // Dimensions from measuring and/or
    // https://datasheets.raspberrypi.com/picow/pico-w-datasheet.pdf
    board_l = pico_board_l;
    board_w = pico_board_w;
    
    hole_x1 = 2.0;
    hole_x2 = board_l - 2.0;
    hole_y_spacing = 11.4;
    hole_y = (board_w - hole_y_spacing)/2;
    
    difference() {
        color("green")
        pico_board();

        pico_hole(hole_d, hole_x1, hole_y);
        pico_hole(hole_d, hole_x2, hole_y);
        pico_hole(hole_d, hole_x1, hole_y + hole_y_spacing);
        pico_hole(hole_d, hole_x2, hole_y + hole_y_spacing);
        
    }
    
    total_l = 52.3;
    total_h = pico_total_h;
    usb_w = 8.0;
    usb_l = 5.6;
    usb_h = 3.0;
    color("lightgray")
    translate([board_l - total_l, (board_w-usb_w)/2, total_h-usb_h])
    cube([usb_l, usb_w, usb_h]);
    
    button_l = 4.2;
    button_w = 3.4;
    button_h = 3.5;
    button_x = 9.9;
    button_y = 5.2;
    color("white")
    translate([button_x, button_y, epsilon])
    cube([button_l, button_w, button_h]);
    
    wifi_l = 10.0;
    wifi_w = 12.0;
    wifi_h = 2.8;
    wifi_x = 33.0;
    color("lightgray")
    translate([wifi_x, (board_w-wifi_w)/2, epsilon])
    cube([wifi_l, wifi_w, wifi_h]);
}

module at_key() {
    translate([pico_board_l + wiring_l, 0, 0])
    rotate([45, 0, 0])
    rotate([0, 90, 0])
    children();
}

module key_interface_shape(thick = key_interface_thickness, outline = thickness) {
    inner = key_interface_size - 2*key_interface_corner_r;
    linear_extrude(thick)
    minkowski() {
        square([inner, inner], center=true);
        circle(r=key_interface_corner_r + outline);
    }
}

module key_interface() {
    at_key()
    difference() {
        key_interface_shape();
        
        translate([0, 0, 6 - epsilon])
        cherry_switch_void(tolerance=0.05);
    }
}

module housing_shape(outline = thickness) {
    inner_squish = housing_inner_h / housing_inner_w;
    housing_w = housing_inner_w + 2 * outline;
    housing_h = housing_inner_h + 2 * outline;
    squish = housing_h / housing_w;

    scale([1, squish])
    circle(d = housing_w);
}

module housing(length = pico_board_l - extra_flare) {
    rotate([90, 0, 0])
    rotate([0, 90, 0])
    linear_extrude(length)
    difference() {
        housing_shape();
        housing_shape(0);
    }
}

module flare_shape(outline, extra_len) {
    hull() {
        at_key()
        key_interface_shape(epsilon + extra_len, outline);
        translate([pico_board_l-extra_flare, 0, 0])

        translate([-extra_len, 0, 0])
        rotate([90, 0, 0])
        rotate([0, 90, 0])
        linear_extrude(epsilon+extra_len)
        housing_shape(outline);
    }
}

module flare() {
    difference() {
        flare_shape(thickness, 0);
        flare_shape(0, epsilon);
    }
}

module at_board() {
    translate([0, -pico_board_w/2, -1])
    children();
}

module tattlekey_case() {
    key_interface();

    difference() {
        union() {
            housing();
            flare();
        }
        at_board()
        pico_board(board_gap);
    }
}

module preview() {
    at_board() pico_w();
    render() tattlekey_case();
}

//preview();

tattlekey_case();