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This commit is contained in:
Nick Estes
2026-08-06 18:42:21 -07:00
parent 69d9b956e6
commit 06cb7f0c4d
35 changed files with 962 additions and 4197 deletions
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cases/gps/source/feather_case.scad
+136 -17
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@@ -48,10 +48,15 @@ battery_diameter = 18;
battery_radial_clearance = 0.6;
battery_end_clearance = 1;
battery_partition_thickness = 1.8;
battery_board_clearance = 3;
rocker_cutout_size = [12.9, 19.4];
rocker_corner_radius = 0.8;
rocker_body_size = [15, 21, 21];
rocker_artwork_gap = 2;
rocker_partition_offset = 2;
rocker_tab_panel_thickness = 2;
rocker_tab_land = 2;
rocker_tab_taper_length = 0.6;
/* [Tripod mount] */
tripod_insert_enabled = false;
@@ -104,10 +109,10 @@ usb_guide_enabled = true;
usb_connector_overhang = 2;
usb_guide_wall_thickness = 1.2;
usb_guide_end_gap = 1;
usb_opening_width = 12.5;
usb_opening_height = 7;
usb_opening_width = 13.5;
usb_opening_height = 8;
usb_opening_radius = 1.5;
usb_vertical_offset = 0;
usb_vertical_offset = 0.5;
/* [Custom wall cutouts] */
// Entry format: [face, shape, u, z, width, height, radius]
@@ -191,7 +196,7 @@ profile_top_gap =
top_profile == "oled128x64" ? oled_face_gap :
generic_top_gap;
partition_y = board_origin_y + feather_width + 1;
partition_y = board_origin_y + feather_width + battery_board_clearance;
battery_center_y = partition_y + battery_partition_thickness
+ battery_radial_clearance + battery_diameter / 2;
battery_start_x = front_lid_boss_center + lid_boss_r
@@ -212,10 +217,14 @@ case_width_battery = battery_center_y + battery_diameter / 2
case_width = battery_enabled ? max(case_width_plain, case_width_battery)
: case_width_plain;
rocker_center_x = case_length - wall_thickness - fit_clearance
rocker_installed_center_x = case_length - wall_thickness - fit_clearance
- lid_lip_thickness - fit_clearance - rocker_body_size[0] / 2;
rocker_center_y = front_lid_boss_center + lid_boss_r + fit_clearance
+ rocker_body_size[1] / 2;
rocker_installed_center_y = front_lid_boss_center + lid_boss_r + fit_clearance
+ rocker_body_size[1] / 2 + rocker_partition_offset;
// The printable lid is flipped across Y when installed, so its local cutout
// coordinate must be mirrored from the assembled switch location.
rocker_lid_center_x = rocker_installed_center_x;
rocker_lid_center_y = case_width - rocker_installed_center_y;
lid_artwork_enabled = lid_label != "" || lid_logo_enabled;
lid_art_rotation =
@@ -223,7 +232,7 @@ lid_art_rotation =
lid_art_orientation == "usb_front" ? 90 :
lid_art_orientation == "usb_right" ? 180 : 270;
lid_art_safe_max_x = battery_enabled
? rocker_center_x - rocker_cutout_size[0] / 2 - rocker_artwork_gap
? rocker_lid_center_x - rocker_cutout_size[0] / 2 - rocker_artwork_gap
: case_length - lid_art_margin;
lid_art_physical_size = [
lid_art_safe_max_x - lid_art_margin,
@@ -294,6 +303,34 @@ lid_boss_xy = [
case_width - wall_thickness - lid_boss_r + lid_boss_wall_overlap
]
];
rocker_boss_clearance = min([
for (p = lid_boss_xy)
sqrt(
pow(max(
abs(p[0] - rocker_installed_center_x)
- rocker_body_size[0] / 2,
0
), 2)
+ pow(max(
abs(p[1] - rocker_installed_center_y)
- rocker_body_size[1] / 2,
0
), 2)
) - lid_boss_r
]);
rocker_relief_half_size = [
rocker_cutout_size[0] / 2,
rocker_cutout_size[1] / 2 + rocker_tab_land + rocker_tab_taper_length
];
rocker_relief_boss_clearance = min([
for (p = lid_boss_xy)
sqrt(
pow(max(abs(p[0] - rocker_lid_center_x)
- rocker_relief_half_size[0], 0), 2)
+ pow(max(abs(p[1] - rocker_lid_center_y)
- rocker_relief_half_size[1], 0), 2)
) - lid_boss_r
]);
assert(wing_count >= 1, "wing_count must be at least one");
assert(top_profile == "generic" || top_profile == "gps"
@@ -301,6 +338,14 @@ assert(top_profile == "generic" || top_profile == "gps"
assert(wall_thickness >= 1.2, "wall_thickness is too small for 0.6 mm FDM");
assert(battery_partition_thickness >= 1.2,
"battery_partition_thickness is too small for 0.6 mm FDM");
assert(battery_board_clearance > 0,
"battery_board_clearance must be positive");
assert(rocker_tab_panel_thickness >= 1.2,
"rocker tab panel needs at least two 0.6 mm lines");
assert(rocker_tab_panel_thickness < lid_thickness,
"rocker tab panel must be thinner than the lid");
assert(rocker_tab_land > 0 && rocker_tab_taper_length > 0,
"rocker tab relief land and taper must be positive");
assert(lid_lip_thickness >= 1.2, "lid lip needs at least two 0.6 mm lines");
assert(lid_art_orientation == "usb_left"
|| lid_art_orientation == "usb_front"
@@ -325,6 +370,13 @@ assert(!tripod_insert_enabled
"Tripod insert boss does not have enough radial material");
assert(usb_opening_enabled || !usb_guide_enabled,
"USB guide requires the USB opening");
assert(!usb_opening_enabled
|| usb_center_z - usb_reserved_height / 2 >= effective_floor,
"USB opening or guide intersects the case floor");
assert(!usb_opening_enabled
|| usb_center_z + usb_reserved_height / 2
<= body_height - lid_lip_depth,
"USB opening or guide intersects the lid lip");
assert(!tripod_insert_enabled
|| tripod_insert_outer_diameter >= tripod_insert_hole_diameter,
"Tripod insert entry must not be smaller than its pilot");
@@ -334,13 +386,35 @@ assert(!battery_enabled || !tripod_insert_enabled
|| tripod_partition_clearance >= 1,
"Tripod insert entry is too close to the battery partition");
assert(!battery_enabled
|| rocker_center_x - rocker_body_size[0] / 2
|| rocker_installed_center_x - rocker_body_size[0] / 2
>= board_origin_x + feather_length + fit_clearance,
"Rocker body overlaps the Feather PCB");
assert(!battery_enabled
|| rocker_center_y + rocker_body_size[1] / 2
|| rocker_installed_center_y + rocker_body_size[1] / 2
<= partition_y - fit_clearance,
"Rocker body overlaps the battery partition");
assert(!battery_enabled
|| rocker_installed_center_x - rocker_body_size[0] / 2
>= wall_thickness + lid_lip_thickness + fit_clearance,
"Rocker body overlaps the front lid lip");
assert(!battery_enabled
|| rocker_installed_center_x + rocker_body_size[0] / 2
<= case_length - wall_thickness - lid_lip_thickness - fit_clearance,
"Rocker body overlaps the rear lid lip");
assert(!battery_enabled
|| rocker_installed_center_y - rocker_body_size[1] / 2
>= wall_thickness + lid_lip_thickness + fit_clearance,
"Rocker body overlaps the Feather-side lid lip");
assert(!battery_enabled || rocker_boss_clearance >= fit_clearance - eps,
"Rocker body overlaps a lid boss");
assert(!battery_enabled
|| rocker_relief_boss_clearance >= fit_clearance - eps,
"Rocker tab relief overlaps a lid boss scallop");
assert(!battery_enabled
|| abs(
case_width - rocker_lid_center_y - rocker_installed_center_y
) < eps,
"Rocker lid cutout does not mirror to the installed switch location");
assert(!battery_enabled
|| body_height - rocker_body_size[2] >= effective_floor,
"Rocker body intersects the case floor");
@@ -803,13 +877,18 @@ module lid_cutouts() {
);
}
if (battery_enabled)
translate([rocker_center_x, rocker_center_y, -eps])
if (battery_enabled) {
translate([rocker_lid_center_x, rocker_lid_center_y, -eps])
centered_rounded_prism(
rocker_cutout_size,
lid_thickness + lid_lip_depth + 2 * eps,
rocker_corner_radius
);
rocker_tab_reliefs(
[rocker_lid_center_x, rocker_lid_center_y],
rocker_cutout_size
);
}
if (top_profile == "oled128x64") {
beveled_oled_window();
@@ -820,6 +899,41 @@ module lid_cutouts() {
}
}
// Thin the horizontal top/bottom edges of the upright switch opening where the
// spring tabs latch. Each full-width land overlaps the rounded opening by its
// corner radius, then extends outward before tapering to the surrounding lid.
module rocker_tab_reliefs(center, opening_size) {
relief_depth = lid_thickness - rocker_tab_panel_thickness;
opening_overlap = rocker_corner_radius;
strip = 0.02;
for (side = [-1, 1]) {
edge_y = center[1] + side * opening_size[1] / 2;
translate([
center[0] - opening_size[0] / 2,
edge_y - (side < 0 ? rocker_tab_land : opening_overlap),
rocker_tab_panel_thickness
])
cube([opening_size[0], rocker_tab_land + opening_overlap,
relief_depth + eps]);
hull() {
translate([
center[0] - opening_size[0] / 2,
edge_y + side * rocker_tab_land - (side < 0 ? strip : 0),
rocker_tab_panel_thickness
])
cube([opening_size[0], strip, relief_depth + eps]);
translate([
center[0] - opening_size[0] / 2,
edge_y + side * (rocker_tab_land + rocker_tab_taper_length)
- (side < 0 ? strip : 0),
lid_thickness - strip
])
cube([opening_size[0], strip, strip + eps]);
}
}
}
module lid_artwork_nominal_2d() {
translate(lid_art_center)
rotate(lid_art_rotation)
@@ -983,15 +1097,15 @@ module reference_battery_and_switch() {
cylinder(h = battery_length, d = battery_diameter);
color([0.08, 0.08, 0.08, 0.85])
translate([
rocker_center_x - rocker_body_size[0] / 2,
rocker_center_y - rocker_body_size[1] / 2,
rocker_installed_center_x - rocker_body_size[0] / 2,
rocker_installed_center_y - rocker_body_size[1] / 2,
body_height + exploded_view - rocker_body_size[2]
])
cube(rocker_body_size);
color([0.12, 0.12, 0.12, 0.95])
translate([
rocker_center_x - rocker_cutout_size[0] / 2,
rocker_center_y - rocker_cutout_size[1] / 2,
rocker_installed_center_x - rocker_cutout_size[0] / 2,
rocker_installed_center_y - rocker_cutout_size[1] / 2,
body_height + exploded_view + lid_thickness
])
cube([rocker_cutout_size[0], rocker_cutout_size[1], 2.5]);
@@ -1049,7 +1163,7 @@ module switch_coupon() {
coupon_height = lid_thickness;
difference() {
rounded_box([coupon_length, coupon_width, coupon_height], 3);
for (i = [0 : len(coupon_steps) - 1])
for (i = [0 : len(coupon_steps) - 1]) {
translate([6 + i * spacing, coupon_width / 2, -eps])
centered_rounded_prism(
rocker_cutout_size
@@ -1057,6 +1171,11 @@ module switch_coupon() {
coupon_height + 2 * eps,
rocker_corner_radius
);
rocker_tab_reliefs(
[6 + i * spacing, coupon_width / 2],
rocker_cutout_size + [coupon_steps[i], coupon_steps[i]]
);
}
}
}