Much improvement case build process

Hardware/Case/bottom_plate.scad

@@ -1,3 +0,0 @@
-use <case.scad>;
-
-bottom_plate_outline();

Hardware/Case/bottom_ring.scad

@@ -1,6 +0,0 @@
-use <case.scad>;
-
-difference() {
-    bottom_ring_outline();
-    mcu_hole();
-}

Hardware/Case/box.scad

@@ -0,0 +1,99 @@
+use <case.scad>;
+
+$fn=128;
+
+// to easily automate exports
+produce = 0;
+if(produce == 0)
+    render();
+else if(produce == 1)
+    bottom_padding();
+else if(produce == 2)
+    mainCuts();
+else if(produce == 3)
+    padding();
+
+knobOffset = 74;
+knobY = -83;
+main_thickness = 37.5;
+bottom_thickness = 5;
+padding_thickness = 12;
+
+encoders = [[-64,0.4],
+            [ 64,0.4]];
+encoderShaftHole = 5.5;
+
+finger = 20;
+fingerX = -75;
+fingerY = -25;
+
+squeeze = 0; // so things are held tight
+gap = 1; // for the top cover
+
+size = [180, 140];
+
+module mainCuts() {
+    difference() {
+        translate([0,-30])
+        square(size, center = true);
+        
+        offset(delta = -squeeze)
+        board();
+        
+        translate([-knobOffset, knobY])
+            circle(d = 25 - squeeze);
+        translate([knobOffset,knobY])
+            circle(d = 25 - squeeze);
+
+        translate([0, 15])
+        square([80, 3], center = true);
+        
+        translate([0, 28])
+        square([100, 13], center = true);
+        
+        translate([fingerX,fingerY])
+        circle(d=finger);
+        translate([-fingerX,fingerY])
+        circle(d=finger);
+    }
+}
+
+module padding() {
+    difference() {
+        offset(delta = -gap)
+        board();
+        
+        for(e = encoders) {
+            translate(e)
+            circle(d=encoderShaftHole);
+        }
+    }
+}
+
+module bottom_padding() {
+    square(size, center = true);
+}
+
+module render() {
+    full_stack(false);
+    
+    color([0.3,0.3,0.3,0.9])
+    linear_extrude(main_thickness)
+        mainCuts();
+    
+    color([0.3,0.3,0.3,0.9])
+    // extra 1 for visualisation purposes
+    translate([0,-30,-bottom_thickness-1])
+    linear_extrude(bottom_thickness)
+    bottom_padding();
+    
+    color([0.3,0.3,0.3,0.9])
+    translate([0, 0, 25.5])
+    linear_extrude(padding_thickness)
+    padding();
+    
+    translate([-knobOffset, knobY])
+        encoder_knob();
+    translate([knobOffset,knobY])
+        encoder_knob();
+}

Hardware/Case/build.bat

@@ -1,7 +0,0 @@
-@echo off
-SET scad="C:\Program Files\OpenSCAD\openscad.exe"
-SET folder=outputs
-
-for %%i in (bottom_plate,bottom_ring,top_plate,top_plate_holes,top_plate_outline,top_ring,holes_internal,holes_surface) DO (
-    %scad% -o "%folder%\%%i.dxf" "%%i.scad"
-)

Hardware/Case/build_box.bat

@@ -0,0 +1,9 @@
+@echo off
+SET scad="C:\Program Files\OpenSCAD\openscad.exe"
+SET folder=outputs
+
+@echo on
+%scad% -o "%folder%\layer0_5mm_box_bottom.dxf" "box.scad" -D produce=1 
+%scad% -o "%folder%\layer1_37.5mm_box_middle.dxf" "box.scad" -D produce=2
+%scad% -o "%folder%\layer1.5_12mm_box_insert.dxf" "box.scad" -D produce=3
+pause

Hardware/Case/build_case.bat

@@ -0,0 +1,17 @@
+@echo off
+SET scad="C:\Program Files\OpenSCAD\openscad.exe"
+SET folder=outputs
+
+REM fiducials are for stacking layers - my software centers the piece,
+REM which results in imperfect alignment. Delete them afterwards
+REM set to 0 if your software can handle coords properly
+SET fiducials=1
+
+for %%i in (bottom_plate,bottom_spacer,top_spacer,top_spacer_engrave,top_plate,top_plate_engrave) DO (
+    @echo on
+    %scad% -o "%folder%\%%i.dxf" "case.scad" -D enable_fiducials=%fiducials% -D "build=\"%%i\""
+)
+
+%scad% -o "%folder%\render.png" "case.scad" -D "build=\"render\"" --imgsize=1920,1080 --camera=-9.47,-33.79,17.17,40.30,0.00,313.60,400 --projection=p
+
+REM pause

Hardware/Case/case.scad

@@ -17,7 +17,8 @@ bolts = [[30.025, 6.65],
          [71, 16.5],
          [42.732, -82.791],
          // Middle hole, remove if not needed
-         [0, -37.592]];
+         //[0, -37.592]
+         ];
 // Not the encoders themselves, but the circle that surrounds them
 encoders = [[-64,0.4],
             [ 64,0.4]];
@@ -25,11 +26,11 @@ encoderRadius = 13;
 
 // encoder solder points hit the case unless we cut these out
 // x, y, hole size
-encoderHoles = [[-8, 0, 3],
-                [ 8, 0, 3]];
+encoderHoles = [[-8, 0, 4],
+                [ 8, 0, 4]];
 // the 3 A/B/Gnd connections + room for their decoupling caps
 // x (mirrored), y, hole size
-encoderHull = [5, -11, 5];
+encoderHull = [5, -11.2, 5];
 
 // x, y, rotation
 leds = [[-26.475, -13.625, 35],
@@ -181,19 +182,37 @@ module encoder_holes() {
     }
 }
 
-module encoder_model() {
+module encoder_knob() {
+    color([0.7,0.7,0.7])
+    cylinder(20, d = 25);
+}
+
+module encoder_model(knob = true) {
     translate([0,0,5.5])
     rotate([90,0,0])
     import("imports/PEC16.stl");
     
-    translate([0,0,13])
-    cylinder(20, d = 25);
+    // Shaft
+    encoderShaft = 6;
+    encoderFlat = 4.5;
+    translate([0,0,6.5])
+    linear_extrude(20)
+    intersection() {
+        circle(d = encoderShaft);
+        translate([0, (encoderShaft-encoderFlat)/2])
+        square([encoderShaft, encoderFlat], center = true);
+    }
+    
+    if(knob) {
+        translate([0,0,13.5])
+        encoder_knob();
+    }
 }
 
-module encoder_model_full() {
+module encoder_model_full(knob = true) {
     for(enc = encoders) {
         translate([enc[0], enc[1]])
-        encoder_model();
+        encoder_model(knob);
     }
 }
 
@@ -295,6 +314,22 @@ module top_ring_outline() {
     board_encoderhole();
 }
 
+// go in intervals of 2 to avoid final implicit union()
+// start at 0.3 because laser kerf
+module top_ring_engrave() {
+    engraveInterval = 0.05;
+    wallOverlap = 1;
+    for(i = [0.3:engraveInterval*2:wallOverlap+engraveInterval]) {
+        difference() {
+            offset(delta=-i)
+            top_ring_outline();
+            
+            offset(delta=-(i+engraveInterval))
+            top_ring_outline();
+        }
+    }
+}
+
 module top_ring() {
     difference() {
         top_ring_outline();
@@ -329,9 +364,9 @@ module mcu_hole() {
     polygon([[-13.3, 3.9],
              [-13.3, -8],
              [-20.15, -17],
-             [-33.65, -17],
-             [-40.5, -8],
-             [-40.5, 3.9]]);
+             [-28.65, -17],
+             [-35.5, -8],
+             [-35.5, 3.9]]);
 }
 
 module bottom_ring() {
@@ -367,7 +402,7 @@ module art_trimmed() {
 }
 
 // This is kinda disgusting
-module full_stack() {
+module full_stack(knobs = true) {
     // quadratic ease out
     t = $t -1;
     boom = -explodeFactor * (t*t*t*t - 1);
@@ -376,7 +411,7 @@ module full_stack() {
     linear_extrude(plate_thickness[0])
         bottom_plate();
     translate([0, 0, plate_thickness[0] + boom]) {
-        color([1, 1, 1, 0.4])
+        color([0.8, 0.8, 0.8, 0.4])
         linear_extrude(plate_thickness[1])
             bottom_ring();
         translate([0, 0, plate_thickness[1] + boom]) {
@@ -392,7 +427,7 @@ module full_stack() {
                 // pretty models of stuff
                 translate([0, 0, boom*2]) {
                     color([0.8,0.8,0.8,1])
-                    encoder_model_full();
+                    encoder_model_full(knobs);
                     
                     switch_models();
                     switch_keycaps();
@@ -421,13 +456,55 @@ module full_stack() {
     
 }
 
-//board();
-full_stack();
+fiducialPoints = [
+    [-80, -100],
+    [80, -100],
+    [-80, 50],
+    [80, 50]
+];
+
+module fiducials() {
+    for(f = fiducialPoints) {
+        translate(f)
+        square(5, center=true);
+    }
+}
+// override in commandline
+build = "render";
+enable_fiducials = 0;
+if(build == "render") {
+    full_stack();
+} else if(build == "bottom_plate") {
+    bottom_plate();
+} else if(build == "bottom_spacer") {
+    bottom_ring();
+} else if(build == "top_spacer") {
+    if(enable_fiducials)
+        fiducials();
+    top_ring();
+} else if(build == "top_spacer_engrave") {
+    if(enable_fiducials)
+        fiducials();
+    top_ring_engrave();
+} else if(build == "top_plate") {
+    if(enable_fiducials)
+        fiducials();
+    top_plate();
+} else if(build == "top_plate_engrave") {
+    if(enable_fiducials)
+        fiducials();
+    art_trimmed();
+}
+
+// for inspecting individual plates
 //linear_extrude(plate_thickness[0])
 //    bottom_plate();
 //linear_extrude(plate_thickness[1])
 //    bottom_ring();
 //linear_extrude(plate_thickness[3])
 //    top_ring();
+//translate([0,0,plate_thickness[3]])
+//linear_extrude(1)
+//    top_ring_engrave();
 //linear_extrude(plate_thickness[4])
 //    top_plate();

Hardware/Case/holes_internal.scad

@@ -1,3 +0,0 @@
-use <case.scad>;
-
-bolt_spacers();

Hardware/Case/holes_surface.scad

@@ -1,3 +0,0 @@
-use <case.scad>;
-
-bolts();

Hardware/Case/top_plate.scad

@@ -1,3 +0,0 @@
-use <case.scad>;
-
-top_plate();

Hardware/Case/top_plate_holes.scad

@@ -1,3 +0,0 @@
-use <case.scad>;
-
-top_plate_holes();

Hardware/Case/top_plate_outline.scad

@@ -1,3 +0,0 @@
-use <case.scad>;
-
-top_plate_outline();

Hardware/Case/top_ring.scad

@@ -1,3 +0,0 @@
-use <case.scad>;
-
-top_ring_outline();