case updates

lib/feather_case_wizard/config.rb

@@ -44,10 +44,15 @@ module FeatherCaseWizard
       "battery_radial_clearance" => 0.6,
       "battery_end_clearance" => 1.0,
       "battery_partition_thickness" => 1.8,
+      "battery_board_clearance" => 3.0,
       "rocker_cutout_size" => [12.9, 19.4],
       "rocker_corner_radius" => 0.8,
       "rocker_body_size" => [15.0, 21.0, 21.0],
       "rocker_artwork_gap" => 2.0,
+      "rocker_partition_offset" => 2.0,
+      "rocker_tab_panel_thickness" => 2.0,
+      "rocker_tab_land" => 2.0,
+      "rocker_tab_taper_length" => 0.6,
       "tripod_insert_enabled" => false,
       "tripod_insert_length" => 5.0,
       "tripod_insert_hole_diameter" => 7.2,
@@ -89,10 +94,10 @@ module FeatherCaseWizard
       "lid_label_size" => 5.0,
       "lid_label_logo_gap" => 2.0,
       "lid_art_margin" => 8.5,
-      "usb_opening_width" => 12.5,
-      "usb_opening_height" => 7.0,
+      "usb_opening_width" => 13.5,
+      "usb_opening_height" => 8.0,
       "usb_opening_radius" => 1.5,
-      "usb_vertical_offset" => 0.0
+      "usb_vertical_offset" => 0.5
     }.freeze
 
     ADVANCED_FIELDS = {
@@ -115,8 +120,12 @@ module FeatherCaseWizard
                             tripod_thread_clearance_diameter tripod_boss_diameter],
       "Battery and switch" => %w[battery_length battery_diameter battery_radial_clearance
                                  battery_end_clearance battery_partition_thickness
+                                 battery_board_clearance
                                  rocker_cutout_size rocker_corner_radius
-                                 rocker_body_size rocker_artwork_gap],
+                                 rocker_body_size rocker_artwork_gap
+                                 rocker_partition_offset
+                                 rocker_tab_panel_thickness rocker_tab_land
+                                 rocker_tab_taper_length],
       "USB-C opening" => %w[usb_opening_width usb_opening_height
                             usb_opening_radius usb_vertical_offset usb_connector_overhang
                             usb_guide_wall_thickness usb_guide_end_gap],
@@ -223,7 +232,7 @@ module FeatherCaseWizard
       plain_width = board_origin_y + 22.86 + p["board_side_clearance"] +
                     p["wall_thickness"]
       if p["battery_enabled"]
-        partition_y = board_origin_y + 22.86 + 1
+        partition_y = board_origin_y + 22.86 + p["battery_board_clearance"]
         battery_y = partition_y + p["battery_partition_thickness"] +
                     p["battery_radial_clearance"] + p["battery_diameter"] / 2
         lid_boss_wall_overlap = 0.6
@@ -325,6 +334,11 @@ module FeatherCaseWizard
         parameters["wall_thickness"] < 1.2
       raise ConfigError, "battery_partition_thickness must be at least 1.2 mm" if
         parameters["battery_partition_thickness"] < 1.2
+      raise ConfigError, "rocker_tab_panel_thickness must be at least 1.2 mm" if
+        parameters["rocker_tab_panel_thickness"] < 1.2
+      if parameters["rocker_tab_panel_thickness"] >= parameters["lid_thickness"]
+        raise ConfigError, "rocker_tab_panel_thickness must be less than lid_thickness"
+      end
       raise ConfigError, "lid_lip_thickness must be at least 1.2 mm" if
         parameters["lid_lip_thickness"] < 1.2
       raise ConfigError, "lid_inlay_depth must be less than lid_thickness" if
@@ -338,6 +352,7 @@ module FeatherCaseWizard
               "tripod_insert_outer_diameter must not be smaller than the pilot"
       end
 
+      validate_usb_opening!
       validate_cutouts!
       self
     end
@@ -402,6 +417,19 @@ module FeatherCaseWizard
       validate_cutout_spacing!(bounds, dims)
     end
 
+    def validate_usb_opening!
+      return unless parameters["usb_opening_enabled"]
+
+      dims = dimensions
+      bounds = usb_wall_bounds(dims)
+      if bounds["bottom"] < dims["floor"]
+        raise ConfigError, "USB opening or guide intersects the case floor"
+      end
+      if bounds["top"] > dims["lip_bottom"]
+        raise ConfigError, "USB opening or guide intersects the lid lip"
+      end
+    end
+
     def validate_cutout_spacing!(bounds, dims)
       web = parameters["cutout_min_web"]
       bounds.combination(2) do |first, second|

lib/feather_case_wizard/package_builder.rb

@@ -225,7 +225,7 @@ module FeatherCaseWizard
         plate, and slicing settings in Bambu Studio.
         #{artwork}
       MARKDOWN
-      File.write(stage.join("README.md"), text)
+      File.write(stage.join("README.md"), text.rstrip + "\n")
     end
 
     def install_atomically(stage, destination)