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update some deisng parameters and add new cases

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This commit is contained in:
gravatite
2026-07-29 14:32:22 -07:00
parent 683697604a
commit 45a77885f9
34 changed files with 4602 additions and 79 deletions
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README.md
+36 -10
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@@ -20,7 +20,7 @@ bundle install
Then run:
```bash
bundle exec bin/feather-case
bin/feather-case
```
The menu can create a case, reopen one for dimensional tuning after a test
@@ -38,6 +38,18 @@ Set `OPENSCAD=/path/to/openscad` or `BLENDER=/path/to/blender` when either
program is installed elsewhere. The wizard checks both tools before replacing
an existing package.
The wizard can add clearance beyond either short end of the Feather PCB for
right-angle headers, plug housings, and wire bends. Front clearance moves the
board and its standoffs away from the USB-C wall; rear clearance extends the
opposite end of the case.
USB programming access can be omitted for a closed front wall or paired with
an enclosed plug guide. The guide runs from the wall toward the connector and
automatically stops short based on the configured connector overhang and end
gap. New cases default to a 2 mm USB connector overhang, an enabled wall
opening, and an enabled guide; with the standard 2 mm front clearance the guide
has no inward length and behaves as the normal wall opening.
Each generated directory contains a dependency-free `build.rb`. After copying
that directory to another Ubuntu machine, run `ruby build.rb` to reproduce its
exports and previews. The saved generator source is used by default so a
@@ -105,10 +117,20 @@ openscad -o oled-buttons.stl \
feather_case.scad
```
The standard stack height is `wing_count * wing_pitch`. Set
`stack_height_override` to the measured distance from the Feather PCB top to
the top FeatherWing PCB when using unusual headers. It takes precedence over
the computed height.
The standard stack height is `wing_count * wing_pitch`, with a 12.25 mm default
pitch. Set `stack_height_override` to the measured distance from the top surface
of the Feather PCB to the top surface of the uppermost FeatherWing PCB when
using unusual headers. Do not include components on the Wing; profile-specific
component heights and top gaps are added separately. The measured override
takes precedence over the computed height.
For the 128×64 OLED profile, `oled_component_height` is the height of the
tallest board feature (the switch tops), while `oled_display_height` controls
the display-face reference shown in the assembly preview. The defaults are
2.4 mm and 1.5 mm above the Wing PCB, respectively. The enclosure ceiling
remains based on the taller switches plus `oled_face_gap`, placing the display
face about 1.7 mm below the lid's inner plane. The default 0.7 mm captive-button
contact extension spans most of the 0.8 mm switch-to-lid gap.
## Custom wire egress
@@ -123,11 +145,15 @@ extra_cutouts = [
];
```
Faces are `front`, `rear`, `left`, and `right`. For front/rear faces, `u` is
the global Y coordinate; for left/right faces it is global X. The Z value is
the opening centre. Shapes are `circle`, `rect`, `roundrect`, and `slot`.
Cutouts that enter the floor or lid-lip keepout raise an assertion instead of
silently weakening those features.
Faces are `front` (the USB-C short wall), `rear` (the opposite short wall),
`left` (the plain/non-JST long wall), and `right` (the JST/battery long wall).
For front/rear faces, `u` is the global Y coordinate; for left/right faces it
is global X. The wizard presents this as distance from the selected wall's
left edge while viewing it from outside. The Z value is the opening centre.
Shapes are `circle`, `rect`, `roundrect`, and `slot`. Cutouts that enter the
floor or lid-lip keepout, approach another opening too closely, or overlap the
USB opening or guide keepout raise an assertion instead of silently weakening
those features.
## Calibration
bin/feather-case
+3 -1
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@@ -1,7 +1,9 @@
#!/usr/bin/env ruby
# frozen_string_literal: true
ENV["BUNDLE_GEMFILE"] ||= File.expand_path("../Gemfile", __dir__)
require "bundler/setup"
require_relative "../lib/feather_case_wizard"
exit FeatherCaseWizard::CLI.new.run
cases/attitude-imu-battery/README.md
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@@ -0,0 +1,25 @@
# Attitude IMU - Battery
Generated by the Feather Case Wizard.
- Top profile: `generic`
- FeatherWings: 1
- Battery compartment: yes
- 1/4-20 insert: yes
- Approximate exterior: 93.9 × 57.3 × 35.8 mm
- Formats: 3mf
- Parts: `body`, `lid`
- Custom cutouts: 0
Run `ruby build.rb` in this directory to regenerate exports and previews.
OpenSCAD and Blender must be installed. Set `OPENSCAD` or `BLENDER` to
override their executable paths.
To open the saved Customizer values manually:
```bash
openscad -p parameters.json -P attitude-imu-battery source/feather_case.scad
```
The 3MF files contain portable geometry only. Choose printer, filament,
plate, and slicing settings in Bambu Studio.
cases/attitude-imu-battery/build.rb
Executable
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@@ -0,0 +1,123 @@
#!/usr/bin/env ruby
# frozen_string_literal: true
require "fileutils"
require "json"
require "open3"
require "pathname"
require "tmpdir"
require "yaml"
ROOT = Pathname(__dir__).expand_path
def executable(env_name, command)
override = ENV[env_name]
return File.expand_path(override) if override && File.executable?(override)
ENV.fetch("PATH", "").split(File::PATH_SEPARATOR).each do |directory|
candidate = File.join(directory, command)
return candidate if File.file?(candidate) && File.executable?(candidate)
end
nil
end
def literal(value)
case value
when String then JSON.generate(value)
when TrueClass then "true"
when FalseClass then "false"
when Numeric then value.to_s
when Array then "[#{value.map { |item| literal(item) }.join(",")}]"
else raise "Cannot convert #{value.inspect} to OpenSCAD"
end
end
def run!(*command, env: {})
stdout, stderr, status = Open3.capture3(env, *command)
return if status.success?
warn [stdout, stderr].reject(&:empty?).join("\n")
raise "Command failed (#{status.exitstatus}): #{command.first}"
end
config = YAML.safe_load_file(ROOT.join("case.yml"), permitted_classes: [],
permitted_symbols: [], aliases: false)
openscad = executable("OPENSCAD", "openscad")
blender = executable("BLENDER", "blender")
abort "OpenSCAD not found; install it or set OPENSCAD" unless openscad
abort "Blender not found; install it or set BLENDER" unless blender
parameters = config.fetch("parameters").merge(
"extra_cutouts" => config.fetch("resolved").fetch("extra_cutouts")
)
parts = %w[body lid] + config.fetch("outputs").fetch("coupons")
buttons = %w[button_a button_b button_c button_reset]
if parameters["top_profile"] == "oled128x64" &&
buttons.any? { |name| parameters[name] }
parts << "buttons"
end
stage = Pathname(Dir.mktmpdir(".rebuild-", ROOT.to_s))
begin
exports = stage.join("exports")
previews = stage.join("previews")
scratch = stage.join("meshes")
FileUtils.mkdir_p([exports, previews, scratch])
model = ROOT.join("source/feather_case.scad")
renderer = ROOT.join("source/render_stl_previews.py")
export = lambda do |output, part, overrides = {}|
values = parameters.merge(overrides).merge("part" => part)
command = [openscad, "-o", output.to_s]
values.each { |name, value| command.concat(["-D", "#{name}=#{literal(value)}"]) }
run!(*command, model.to_s)
end
config.fetch("outputs").fetch("formats").each do |format|
directory = exports.join(format)
FileUtils.mkdir_p(directory)
parts.each do |part|
puts "Exporting #{part}.#{format}…"
export.call(directory.join("#{part}.#{format}"), part)
end
end
assembly = scratch.join("assembly.stl")
puts "Preparing assembly preview…"
export.call(assembly, "assembly",
"exploded_view" => config.fetch("outputs").fetch("assembly_exploded_view"),
"show_references" => false)
render_env = {"DISPLAY" => nil, "WAYLAND_DISPLAY" => nil}
run!(blender, "--background", "-noaudio", "--python", renderer.to_s, "--",
assembly.to_s, previews.to_s, "assembly", env: render_env)
parts.each do |part|
puts "Rendering #{part} preview…"
mesh = scratch.join("#{part}.stl")
export.call(mesh, part) unless mesh.file?
run!(blender, "--background", "-noaudio", "--python", renderer.to_s, "--",
mesh.to_s, previews.to_s, part, "iso", env: render_env)
end
backup = ROOT.join(".build-old-#{Process.pid}")
FileUtils.mkdir_p(backup)
%w[exports previews].each do |name|
current = ROOT.join(name)
FileUtils.mv(current, backup.join(name)) if current.exist?
end
begin
FileUtils.mv(exports, ROOT.join("exports"))
FileUtils.mv(previews, ROOT.join("previews"))
FileUtils.rm_rf(backup)
rescue StandardError
FileUtils.rm_rf(ROOT.join("exports"))
FileUtils.rm_rf(ROOT.join("previews"))
%w[exports previews].each do |name|
saved = backup.join(name)
FileUtils.mv(saved, ROOT.join(name)) if saved.exist?
end
raise
end
puts "Rebuilt #{ROOT}"
ensure
FileUtils.rm_rf(stage)
end
cases/attitude-imu-battery/case.yml
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@@ -0,0 +1,82 @@
---
schema_version: 1
name: Attitude IMU - Battery
slug: attitude-imu-battery
generator:
sha256: be611e3255e7d802719ebb0628e3d11481f8de05fc96c24d452f026d7b8e3353
created_with: feather-case-wizard
parameters:
top_profile: generic
wing_count: 1
wing_pitch: 12.25
stack_height_override: 0.0
generic_component_height: 3.0
generic_top_gap: 2.0
gps_antenna_height: 6.0
gps_top_gap: 5.0
oled_component_height: 2.4
oled_display_height: 1.5
oled_face_gap: 0.8
button_a: true
button_b: true
button_c: true
button_reset: false
button_projection: 1.5
button_cap_size:
- 5.0
- 3.2
button_flange_size:
- 6.6
- 3.6
button_flange_thickness: 0.9
button_travel: 0.5
button_contact_extension: 0.7
battery_enabled: true
battery_length: 69.0
battery_diameter: 18.0
battery_radial_clearance: 0.6
battery_end_clearance: 1.0
switch_hole_diameter: 12.0
switch_hole_compensation: 0.3
switch_cap_diameter: 8.0
switch_flange_diameter: 16.2
switch_body_length: 24.0
switch_body_diameter: 12.0
switch_wire_allowance: 3.0
tripod_insert_enabled: true
tripod_insert_length: 6.4
tripod_insert_hole_diameter: 8.8
tripod_thread_clearance_diameter: 6.8
tripod_boss_diameter: 14.0
m25_insert_length: 4.0
m25_insert_hole_diameter: 3.7
m25_screw_clearance: 2.8
m25_boss_diameter: 7.0
insert_entry_chamfer: 0.6
insert_melt_relief: 0.8
wall_thickness: 2.4
floor_thickness: 2.4
lid_thickness: 3.2
corner_radius: 4.0
board_bottom_clearance: 5.4
board_side_clearance: 7.0
board_rear_clearance: 4.0
usb_board_wall_gap: 1.2
lid_lip_depth: 2.4
lid_lip_thickness: 1.2
fit_clearance: 0.35
hole_compensation: 0.2
lid_screw_head_diameter: 5.2
lid_screw_head_height: 2.5
usb_opening_width: 12.5
usb_opening_height: 7.0
usb_opening_radius: 1.5
usb_vertical_offset: 0.0
cutouts: []
outputs:
formats:
- 3mf
coupons: []
assembly_exploded_view: 8
resolved:
extra_cutouts: []
cases/attitude-imu-battery/parameters.json
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@@ -0,0 +1,69 @@
{
"parameterSets": {
"attitude-imu-battery": {
"top_profile": "\"generic\"",
"wing_count": "1",
"wing_pitch": "12.25",
"stack_height_override": "0.0",
"generic_component_height": "3.0",
"generic_top_gap": "2.0",
"gps_antenna_height": "6.0",
"gps_top_gap": "5.0",
"oled_component_height": "2.4",
"oled_display_height": "1.5",
"oled_face_gap": "0.8",
"button_a": "true",
"button_b": "true",
"button_c": "true",
"button_reset": "false",
"button_projection": "1.5",
"button_cap_size": "[5.0,3.2]",
"button_flange_size": "[6.6,3.6]",
"button_flange_thickness": "0.9",
"button_travel": "0.5",
"button_contact_extension": "0.7",
"battery_enabled": "true",
"battery_length": "69.0",
"battery_diameter": "18.0",
"battery_radial_clearance": "0.6",
"battery_end_clearance": "1.0",
"switch_hole_diameter": "12.0",
"switch_hole_compensation": "0.3",
"switch_cap_diameter": "8.0",
"switch_flange_diameter": "16.2",
"switch_body_length": "24.0",
"switch_body_diameter": "12.0",
"switch_wire_allowance": "3.0",
"tripod_insert_enabled": "true",
"tripod_insert_length": "6.4",
"tripod_insert_hole_diameter": "8.8",
"tripod_thread_clearance_diameter": "6.8",
"tripod_boss_diameter": "14.0",
"m25_insert_length": "4.0",
"m25_insert_hole_diameter": "3.7",
"m25_screw_clearance": "2.8",
"m25_boss_diameter": "7.0",
"insert_entry_chamfer": "0.6",
"insert_melt_relief": "0.8",
"wall_thickness": "2.4",
"floor_thickness": "2.4",
"lid_thickness": "3.2",
"corner_radius": "4.0",
"board_bottom_clearance": "5.4",
"board_side_clearance": "7.0",
"board_rear_clearance": "4.0",
"usb_board_wall_gap": "1.2",
"lid_lip_depth": "2.4",
"lid_lip_thickness": "1.2",
"fit_clearance": "0.35",
"hole_compensation": "0.2",
"lid_screw_head_diameter": "5.2",
"lid_screw_head_height": "2.5",
"usb_opening_width": "12.5",
"usb_opening_height": "7.0",
"usb_opening_radius": "1.5",
"usb_vertical_offset": "0.0"
}
},
"fileFormatVersion": "1"
}
cases/attitude-imu-battery/source/feather_case.scad
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/*
* Parametric enclosure for the Adafruit ESP32 Feather V2 and FeatherWings.
*
* Coordinate system:
* X: USB-C wall (0) toward the rear of the case
* Y: non-battery side (0) toward the battery/JST side
* Z: outside bottom (0) upward
*
* Board coordinates are derived from Adafruit's Eagle PCB files:
* https://github.com/adafruit/Adafruit-ESP32-Feather-V2-PCB
* https://github.com/adafruit/Adafruit-OLED-FeatherWing-PCB
*/
/* [Output] */
part = "assembly"; // [assembly,body,lid,buttons,insert_coupon,switch_coupon,fit_coupon]
exploded_view = 8; // [0:1:20]
show_references = true;
/* [Stack] */
top_profile = "generic"; // [generic,gps,oled128x64]
wing_count = 1; // [1:1:8]
wing_pitch = 12.25; // [7:0.1:16]
stack_height_override = 0; // [0:0.1:100]
generic_component_height = 3; // [0:0.1:30]
generic_top_gap = 2; // [0.5:0.1:10]
gps_antenna_height = 6;
gps_top_gap = 5;
oled_component_height = 2.4;
oled_display_height = 1.5;
oled_face_gap = 0.8;
/* [OLED controls] */
button_a = true;
button_b = true;
button_c = true;
button_reset = false;
button_projection = 1.5; // [0.5:0.1:3]
button_cap_size = [5, 3.2];
button_flange_size = [6.6, 3.6];
button_flange_thickness = 0.9;
button_travel = 0.5;
button_contact_extension = 0.7;
/* [Battery and switch] */
battery_enabled = false;
battery_length = 69;
battery_diameter = 18;
battery_radial_clearance = 0.6;
battery_end_clearance = 1;
switch_hole_diameter = 12;
switch_hole_compensation = 0.3;
switch_cap_diameter = 8;
switch_flange_diameter = 16.2;
switch_body_length = 24;
switch_body_diameter = 12;
switch_wire_allowance = 3;
/* [Tripod mount] */
tripod_insert_enabled = false;
tripod_insert_length = 6.4;
tripod_insert_hole_diameter = 8.8;
tripod_thread_clearance_diameter = 6.8;
tripod_boss_diameter = 14;
/* [M2.5 inserts] */
m25_insert_length = 4;
m25_insert_hole_diameter = 3.7;
m25_screw_clearance = 2.8;
m25_boss_diameter = 7;
insert_entry_chamfer = 0.6;
insert_melt_relief = 0.8;
/* [Shell and fit] */
wall_thickness = 2.4;
floor_thickness = 2.4;
lid_thickness = 3.2;
corner_radius = 4;
board_bottom_clearance = 5.4;
board_side_clearance = 7;
board_rear_clearance = 4;
usb_board_wall_gap = 1.2;
lid_lip_depth = 2.4;
lid_lip_thickness = 1.2;
fit_clearance = 0.35;
hole_compensation = 0.2;
lid_screw_head_diameter = 5.2;
lid_screw_head_height = 2.5;
/* [USB-C opening] */
usb_opening_width = 12.5;
usb_opening_height = 7;
usb_opening_radius = 1.5;
usb_vertical_offset = 0;
/* [Custom wall cutouts] */
// Entry format: [face, shape, u, z, width, height, radius]
// face: front, rear, left, right. u is Y on front/rear and X on left/right.
// shape: circle, rect, roundrect, slot. Circle uses width as its diameter.
extra_cutouts = [];
/* [Calibration] */
coupon_steps = [-0.3, -0.15, 0, 0.15, 0.3];
$fn = $preview ? 36 : 72;
eps = 0.02;
// Adafruit Feather mechanical reference, millimetres.
feather_length = 50.8;
feather_width = 22.86;
board_thickness = 1.6;
mount_x = [2.54, 48.26];
mount_y = [2.54, 20.32];
usb_center_y = 11.43;
// Official 128x64 OLED FeatherWing geometry in Feather-board coordinates.
oled_visible_min = [11.42, 3.78];
oled_visible_size = [30, 15.3];
oled_button_a_xy = [4.318, 15.875];
oled_button_b_xy = [4.318, 11.43];
oled_button_c_xy = [4.318, 6.985];
oled_button_reset_xy = [7.366, 20.828];
effective_floor = tripod_insert_enabled
? max(floor_thickness, tripod_insert_length + insert_melt_relief + 1.2)
: floor_thickness;
effective_board_clearance = max(
board_bottom_clearance,
m25_insert_length + insert_melt_relief + 0.6
);
board_origin_x = wall_thickness + usb_board_wall_gap;
board_origin_y = wall_thickness + board_side_clearance;
board_bottom_z = effective_floor + effective_board_clearance;
board_top_z = board_bottom_z + board_thickness;
computed_top_pcb_z = board_top_z + wing_count * wing_pitch;
top_pcb_z = stack_height_override > 0
? board_top_z + stack_height_override
: computed_top_pcb_z;
profile_component_height =
top_profile == "gps" ? gps_antenna_height :
top_profile == "oled128x64" ? oled_component_height :
generic_component_height;
profile_top_gap =
top_profile == "gps" ? gps_top_gap :
top_profile == "oled128x64" ? oled_face_gap :
generic_top_gap;
partition_y = board_origin_y + feather_width + 1;
battery_center_y = partition_y + wall_thickness + battery_radial_clearance
+ battery_diameter / 2;
battery_start_x = board_origin_x + battery_end_clearance;
battery_end_x = battery_start_x + battery_length;
switch_center_x = battery_end_x + max(
switch_body_diameter / 2 + 0.8,
switch_flange_diameter / 2 + 0.5
);
case_length_plain = board_origin_x + feather_length
+ board_rear_clearance + wall_thickness;
case_length_battery = switch_center_x + switch_flange_diameter / 2
+ 1.2 + wall_thickness;
case_length = battery_enabled ? max(case_length_plain, case_length_battery)
: case_length_plain;
case_width_plain = board_origin_y + feather_width
+ board_side_clearance + wall_thickness;
case_width_battery = battery_center_y + battery_diameter / 2
+ battery_radial_clearance + wall_thickness;
case_width = battery_enabled ? max(case_width_plain, case_width_battery)
: case_width_plain;
battery_center_z = effective_floor + battery_radial_clearance
+ battery_diameter / 2;
switch_center_z = max(
effective_floor + switch_flange_diameter / 2 + 1,
battery_center_z
);
electronics_ceiling_z = top_pcb_z + profile_component_height + profile_top_gap;
battery_ceiling_z = battery_enabled
? max(
battery_center_z + battery_diameter / 2 + battery_radial_clearance,
switch_center_z + switch_flange_diameter / 2 + 1
)
: 0;
body_height = max(electronics_ceiling_z, battery_ceiling_z);
lid_boss_r = m25_boss_diameter / 2;
lid_boss_wall_overlap = 0.6;
lid_boss_xy = [
[
wall_thickness + lid_boss_r - lid_boss_wall_overlap,
wall_thickness + lid_boss_r - lid_boss_wall_overlap
],
[
case_length - wall_thickness - lid_boss_r + lid_boss_wall_overlap,
wall_thickness + lid_boss_r - lid_boss_wall_overlap
],
[
wall_thickness + lid_boss_r - lid_boss_wall_overlap,
case_width - wall_thickness - lid_boss_r + lid_boss_wall_overlap
],
[
case_length - wall_thickness - lid_boss_r + lid_boss_wall_overlap,
case_width - wall_thickness - lid_boss_r + lid_boss_wall_overlap
]
];
assert(wing_count >= 1, "wing_count must be at least one");
assert(top_profile == "generic" || top_profile == "gps"
|| top_profile == "oled128x64", "Unsupported top_profile");
assert(wall_thickness >= 1.2, "wall_thickness is too small for 0.6 mm FDM");
assert(lid_lip_thickness >= 1.2, "lid lip needs at least two 0.6 mm lines");
assert(m25_boss_diameter > m25_insert_hole_diameter + 2,
"M2.5 boss does not have enough radial material");
assert(!tripod_insert_enabled
|| tripod_boss_diameter > tripod_insert_hole_diameter + 3,
"Tripod insert boss does not have enough radial material");
function clamp(v, lo, hi) = min(max(v, lo), hi);
module rounded_rect_2d(size, radius) {
r = clamp(radius, 0.01, min(size[0], size[1]) / 2 - 0.01);
hull() {
for (x = [r, size[0] - r], y = [r, size[1] - r])
translate([x, y]) circle(r = r);
}
}
module centered_rounded_rect_2d(size, radius) {
translate([-size[0] / 2, -size[1] / 2])
rounded_rect_2d(size, radius);
}
module centered_rounded_prism(size, height, radius) {
linear_extrude(height = height)
centered_rounded_rect_2d(size, radius);
}
module rounded_box(size, radius) {
linear_extrude(height = size[2])
rounded_rect_2d([size[0], size[1]], radius);
}
module insert_pocket(diameter, depth, entry_z, downward = true) {
bore_d = diameter + hole_compensation;
if (downward) {
translate([0, 0, entry_z - depth])
cylinder(h = depth + eps, d = bore_d);
translate([0, 0, entry_z - insert_entry_chamfer])
cylinder(
h = insert_entry_chamfer + eps,
d1 = bore_d,
d2 = bore_d + 2 * insert_entry_chamfer
);
} else {
translate([0, 0, entry_z - eps])
cylinder(h = depth + eps, d = bore_d);
translate([0, 0, entry_z - eps])
cylinder(
h = insert_entry_chamfer + eps,
d1 = bore_d + 2 * insert_entry_chamfer,
d2 = bore_d
);
}
}
module face_rounded_cutout(face, u, z, width, height, radius) {
r = clamp(radius, 0.01, min(width, height) / 2);
depth = wall_thickness + 2 * eps;
if (face == "front" || face == "rear") {
x0 = face == "front" ? -eps : case_length - wall_thickness - eps;
hull()
for (yy = [u - width / 2 + r, u + width / 2 - r],
zz = [z - height / 2 + r, z + height / 2 - r])
translate([x0, yy, zz])
rotate([0, 90, 0]) cylinder(h = depth, r = r);
} else if (face == "left" || face == "right") {
y0 = face == "left" ? -eps : case_width - wall_thickness - eps;
hull()
for (xx = [u - width / 2 + r, u + width / 2 - r],
zz = [z - height / 2 + r, z + height / 2 - r])
translate([xx, y0, zz])
rotate([-90, 0, 0]) cylinder(h = depth, r = r);
}
}
module face_circle_cutout(face, u, z, diameter) {
depth = wall_thickness + 2 * eps;
if (face == "front")
translate([-eps, u, z])
rotate([0, 90, 0]) cylinder(h = depth, d = diameter);
else if (face == "rear")
translate([case_length - wall_thickness - eps, u, z])
rotate([0, 90, 0]) cylinder(h = depth, d = diameter);
else if (face == "left")
translate([u, -eps, z])
rotate([-90, 0, 0]) cylinder(h = depth, d = diameter);
else if (face == "right")
translate([u, case_width - wall_thickness - eps, z])
rotate([-90, 0, 0]) cylinder(h = depth, d = diameter);
}
module custom_wall_cutout(entry) {
face = entry[0];
shape = entry[1];
u = entry[2];
z = entry[3];
width = entry[4];
height = len(entry) > 5 ? entry[5] : width;
radius = len(entry) > 6 ? entry[6] : min(width, height) / 2;
assert(face == "front" || face == "rear"
|| face == "left" || face == "right", "Invalid cutout face");
assert(shape == "circle" || shape == "rect"
|| shape == "roundrect" || shape == "slot", "Invalid cutout shape");
assert(z - height / 2 >= effective_floor,
"Cutout intersects the floor");
assert(z + height / 2 <= body_height - lid_lip_depth,
"Cutout intersects the lid locating lip");
assert(
(face == "front" || face == "rear")
? u - width / 2 >= 0 && u + width / 2 <= case_width
: u - width / 2 >= 0 && u + width / 2 <= case_length,
"Cutout extends beyond its wall"
);
if (shape == "circle")
face_circle_cutout(face, u, z, width);
else
face_rounded_cutout(
face, u, z, width, height,
shape == "rect" ? 0.02 :
shape == "slot" ? min(width, height) / 2 : radius
);
}
module board_standoffs() {
for (mx = mount_x, my = mount_y)
translate([
board_origin_x + mx,
board_origin_y + my,
effective_floor - eps
])
cylinder(
h = effective_board_clearance + eps,
d = m25_boss_diameter
);
}
module lid_bosses() {
for (p = lid_boss_xy)
translate([p[0], p[1], effective_floor - eps])
cylinder(
h = body_height - effective_floor + eps,
d = m25_boss_diameter
);
}
module battery_cradle() {
partition_height = min(
body_height - lid_lip_depth - 0.5,
battery_center_z + battery_diameter / 2 + 1.5
);
rib_width = 2.4;
rib_positions = [
battery_start_x + 4,
(battery_start_x + battery_end_x) / 2,
battery_end_x - 4
];
// Board/battery partition, with a lead-routing notch near the JST end.
difference() {
translate([wall_thickness, partition_y, effective_floor - eps])
cube([
battery_end_x - wall_thickness + battery_end_clearance,
wall_thickness,
partition_height - effective_floor + eps
]);
translate([
board_origin_x + 6.5,
partition_y - eps,
effective_floor + 1.5
])
cube([9, wall_thickness + 2 * eps, 6]);
}
// Three low curved ribs cradle the protected cylindrical pack.
for (x = rib_positions)
difference() {
translate([
x - rib_width / 2,
battery_center_y - battery_diameter / 2
- battery_radial_clearance,
effective_floor - eps
])
cube([
rib_width,
battery_diameter + 2 * battery_radial_clearance,
battery_diameter / 2 + battery_radial_clearance + eps
]);
translate([x - rib_width, battery_center_y, battery_center_z])
rotate([0, 90, 0])
cylinder(
h = rib_width * 2,
d = battery_diameter + 2 * battery_radial_clearance
);
}
// End stops remain below the cell center so the lid can remove vertically.
for (x = [
battery_start_x - battery_end_clearance - wall_thickness,
battery_end_x + battery_end_clearance
])
translate([
x,
battery_center_y - battery_diameter / 2 - battery_radial_clearance,
effective_floor - eps
])
cube([
wall_thickness,
battery_diameter + 2 * battery_radial_clearance,
battery_diameter / 2 + 1 + eps
]);
// Rear cross-strip separates the side-mounted switch body from the cell.
translate([
battery_end_x + battery_end_clearance,
partition_y,
effective_floor - eps
])
cube([
case_length - wall_thickness - battery_end_x - battery_end_clearance,
case_width - wall_thickness - partition_y,
min(body_height - effective_floor, switch_center_z
+ switch_body_diameter / 2 + switch_wire_allowance
- effective_floor) + eps
]);
}
module body_positive() {
union() {
difference() {
rounded_box([case_length, case_width, body_height], corner_radius);
translate([wall_thickness, wall_thickness, effective_floor])
rounded_box([
case_length - 2 * wall_thickness,
case_width - 2 * wall_thickness,
body_height - effective_floor + eps
], max(0.6, corner_radius - wall_thickness));
}
board_standoffs();
lid_bosses();
if (battery_enabled)
battery_cradle();
if (tripod_insert_enabled)
translate([case_length / 2, case_width / 2, 0])
cylinder(h = effective_floor, d = tripod_boss_diameter);
}
}
module body_cutouts() {
// Board mounting insert pockets, loaded from above before the Feather.
for (mx = mount_x, my = mount_y)
translate([board_origin_x + mx, board_origin_y + my, 0])
insert_pocket(
m25_insert_hole_diameter,
m25_insert_length + insert_melt_relief,
board_bottom_z
);
// Lid insert pockets, loaded from the top of the body.
for (p = lid_boss_xy)
translate([p[0], p[1], 0])
insert_pocket(
m25_insert_hole_diameter,
m25_insert_length + insert_melt_relief,
body_height
);
// USB-C cable opening. Connector center is from the official ESP32 V2 PCB.
usb_center_z = board_top_z + 1.6 + usb_vertical_offset;
face_rounded_cutout(
"front",
board_origin_y + usb_center_y,
usb_center_z,
usb_opening_width + hole_compensation,
usb_opening_height + hole_compensation,
usb_opening_radius
);
if (battery_enabled) {
face_circle_cutout(
"right",
switch_center_x,
switch_center_z,
switch_hole_diameter + switch_hole_compensation
);
// Clear the switch body and its prewired terminals through the rear bay.
translate([
switch_center_x,
case_width - wall_thickness + eps,
switch_center_z
])
rotate([90, 0, 0])
cylinder(
h = switch_body_length + switch_wire_allowance
+ wall_thickness + eps,
d = switch_body_diameter + 2 * fit_clearance
);
}
if (tripod_insert_enabled) {
translate([case_length / 2, case_width / 2, 0]) {
translate([0, 0, -eps])
cylinder(
h = effective_floor + 2 * eps,
d = tripod_thread_clearance_diameter + hole_compensation
);
insert_pocket(
tripod_insert_hole_diameter,
tripod_insert_length + insert_melt_relief,
effective_floor
);
}
}
for (entry = extra_cutouts)
custom_wall_cutout(entry);
}
module body() {
difference() {
body_positive();
body_cutouts();
}
}
module lid_plate_positive() {
union() {
rounded_box([case_length, case_width, lid_thickness], corner_radius);
// Inset rim: exported pointing upward so the outer lid face prints flat.
translate([
wall_thickness + fit_clearance,
wall_thickness + fit_clearance,
lid_thickness
])
linear_extrude(height = lid_lip_depth)
difference() {
rounded_rect_2d([
case_length - 2 * (wall_thickness + fit_clearance),
case_width - 2 * (wall_thickness + fit_clearance)
], max(0.6, corner_radius - wall_thickness));
translate([lid_lip_thickness, lid_lip_thickness])
rounded_rect_2d([
case_length - 2 * (
wall_thickness + fit_clearance
+ lid_lip_thickness
),
case_width - 2 * (
wall_thickness + fit_clearance
+ lid_lip_thickness
)
], max(0.5, corner_radius - wall_thickness
- lid_lip_thickness));
}
}
}
module beveled_oled_window() {
inner_size = oled_visible_size;
outer_size = [oled_visible_size[0] + 3, oled_visible_size[1] + 3];
center = [
board_origin_x + oled_visible_min[0] + oled_visible_size[0] / 2,
board_origin_y + oled_visible_min[1] + oled_visible_size[1] / 2
];
hull() {
translate([center[0], center[1], -eps])
linear_extrude(height = eps)
centered_rounded_rect_2d(outer_size, 1.5);
translate([center[0], center[1], lid_thickness - eps])
linear_extrude(height = 2 * eps)
centered_rounded_rect_2d(inner_size, 0.8);
}
}
module oled_button_lid_cutout(xy) {
center = [board_origin_x + xy[0], board_origin_y + xy[1]];
shaft_size = [
button_cap_size[0] + fit_clearance * 2,
button_cap_size[1] + fit_clearance * 2
];
recess_size = [
button_flange_size[0] + fit_clearance * 2,
button_flange_size[1] + fit_clearance * 2
];
recess_depth = button_flange_thickness + button_travel;
translate([center[0], center[1], -eps])
centered_rounded_prism(
shaft_size,
lid_thickness + 2 * eps,
shaft_size[1] / 2
);
translate([center[0], center[1], lid_thickness - recess_depth])
centered_rounded_prism(
recess_size,
recess_depth + lid_lip_depth + eps,
recess_size[1] / 2
);
}
module lid_cutouts() {
// Through holes plus shallow counterbores for flush M2.5 socket heads.
for (p = lid_boss_xy) {
translate([p[0], p[1], -eps])
cylinder(
h = lid_thickness + lid_lip_depth + 2 * eps,
d = m25_screw_clearance + hole_compensation
);
translate([p[0], p[1], -eps])
cylinder(
h = lid_screw_head_height + eps,
d = lid_screw_head_diameter + hole_compensation
);
}
if (top_profile == "oled128x64") {
beveled_oled_window();
if (button_a) oled_button_lid_cutout(oled_button_a_xy);
if (button_b) oled_button_lid_cutout(oled_button_b_xy);
if (button_c) oled_button_lid_cutout(oled_button_c_xy);
if (button_reset) oled_button_lid_cutout(oled_button_reset_xy);
}
}
module lid() {
difference() {
lid_plate_positive();
lid_cutouts();
}
}
module one_oled_button() {
recess_depth = button_flange_thickness + button_travel;
stem_height = lid_thickness - recess_depth + button_projection;
// Print outer cap face down. The flange and contact nub build upward.
centered_rounded_prism(
button_cap_size,
stem_height,
button_cap_size[1] / 2
);
translate([0, 0, stem_height])
centered_rounded_prism(
button_flange_size,
button_flange_thickness,
button_flange_size[1] / 2
);
translate([0, 0, stem_height + button_flange_thickness])
cylinder(h = button_contact_extension, d = 3);
}
module buttons() {
enabled = [
button_a,
button_b,
button_c,
button_reset
];
count_enabled = len([for (v = enabled) if (v) 1]);
if (count_enabled == 0)
echo("No OLED buttons are enabled.");
for (i = [0 : len(enabled) - 1])
if (enabled[i])
translate([i * (button_flange_size[0] + 3), 0, 0])
one_oled_button();
}
module reference_board() {
color([0.05, 0.25, 0.55, 0.75])
translate([board_origin_x, board_origin_y, board_bottom_z])
rounded_box([feather_length, feather_width, board_thickness], 2.54);
color([0.12, 0.45, 0.75, 0.45])
for (i = [1 : wing_count])
translate([
board_origin_x,
board_origin_y,
board_top_z + i * wing_pitch - board_thickness
])
rounded_box(
[feather_length, feather_width, board_thickness], 2.54
);
}
module reference_top_feature() {
if (top_profile == "gps")
color([0.92, 0.78, 0.35, 0.8])
translate([
board_origin_x + 31,
board_origin_y + (feather_width - 15) / 2,
top_pcb_z
])
cube([15, 15, gps_antenna_height]);
else if (top_profile == "oled128x64") {
color([0.12, 0.12, 0.12, 0.9])
translate([
board_origin_x + oled_visible_min[0],
board_origin_y + oled_visible_min[1],
top_pcb_z
])
cube([
oled_visible_size[0],
oled_visible_size[1],
oled_display_height
]);
color([0.6, 0.6, 0.6, 0.9])
for (xy = [
oled_button_a_xy,
oled_button_b_xy,
oled_button_c_xy,
oled_button_reset_xy
])
translate([
board_origin_x + xy[0],
board_origin_y + xy[1],
top_pcb_z
])
cylinder(h = 1.6, d = 2.1);
} else
color([0.3, 0.65, 0.35, 0.6])
translate([
board_origin_x + 10,
board_origin_y + 4,
top_pcb_z
])
cube([
feather_length - 20,
feather_width - 8,
generic_component_height
]);
}
module reference_battery_and_switch() {
if (battery_enabled) {
color([0.35, 0.18, 0.55, 0.75])
translate([battery_start_x, battery_center_y, battery_center_z])
rotate([0, 90, 0])
cylinder(h = battery_length, d = battery_diameter);
color([0.8, 0.15, 0.1, 0.65])
translate([
switch_center_x,
case_width - wall_thickness,
switch_center_z
])
rotate([90, 0, 0]) {
cylinder(h = switch_body_length, d = switch_body_diameter);
translate([0, 0, -1.5])
cylinder(h = 1.5, d = switch_flange_diameter);
translate([0, 0, -3])
cylinder(h = 3, d = switch_cap_diameter);
}
}
}
module assembly() {
color([0.82, 0.84, 0.88, 1]) body();
if ($preview && show_references) {
reference_board();
reference_top_feature();
reference_battery_and_switch();
}
// Printable lid is mirrored into its installed orientation and exploded up.
color([0.92, 0.92, 0.95, 0.88])
translate([0, case_width, body_height + lid_thickness + exploded_view])
rotate([180, 0, 0])
lid();
}
module coupon_hole(x, y, diameter, depth) {
translate([x, y, -eps]) cylinder(h = depth + 2 * eps, d = diameter);
}
module insert_coupon() {
spacing = 15;
coupon_length = spacing * len(coupon_steps) + 8;
coupon_width = 32;
coupon_height = max(
m25_insert_length + insert_melt_relief + 1.2,
tripod_insert_length + insert_melt_relief + 1.2
);
difference() {
rounded_box([coupon_length, coupon_width, coupon_height], 3);
for (i = [0 : len(coupon_steps) - 1]) {
x = 7 + i * spacing;
coupon_hole(
x, 8,
m25_insert_hole_diameter + coupon_steps[i],
m25_insert_length + insert_melt_relief
);
coupon_hole(
x, 23,
tripod_insert_hole_diameter + coupon_steps[i],
tripod_insert_length + insert_melt_relief
);
}
}
}
module switch_coupon() {
spacing = 18;
coupon_length = spacing * len(coupon_steps) + 6;
coupon_width = 24;
coupon_height = wall_thickness;
difference() {
rounded_box([coupon_length, coupon_width, coupon_height], 3);
for (i = [0 : len(coupon_steps) - 1])
translate([6 + i * spacing, coupon_width / 2, -eps])
cylinder(
h = coupon_height + 2 * eps,
d = switch_hole_diameter + coupon_steps[i]
);
}
}
module fit_coupon() {
segment_length = 34;
base_width = 16;
base_height = 6;
cavity_size = [segment_length - 8, base_width - 8];
male_size = [
cavity_size[0] - 2 * fit_clearance,
cavity_size[1] - 2 * fit_clearance
];
difference() {
rounded_box([segment_length, base_width, base_height], 2);
translate([4, 4, 2])
cube([segment_length - 8, base_width - 8, base_height]);
}
translate([segment_length + 5, 0, 0])
union() {
cube([segment_length, base_width, lid_thickness]);
translate([
4 + fit_clearance,
4 + fit_clearance,
lid_thickness - eps
])
linear_extrude(height = lid_lip_depth + eps)
difference() {
rounded_rect_2d(male_size, 1);
translate([lid_lip_thickness, lid_lip_thickness])
rounded_rect_2d([
male_size[0] - 2 * lid_lip_thickness,
male_size[1] - 2 * lid_lip_thickness
], 0.5);
}
}
}
if (part == "assembly")
assembly();
else if (part == "body")
body();
else if (part == "lid")
lid();
else if (part == "buttons")
buttons();
else if (part == "insert_coupon")
insert_coupon();
else if (part == "switch_coupon")
switch_coupon();
else if (part == "fit_coupon")
fit_coupon();
else
assert(false, str("Unknown part: ", part));
cases/attitude-imu-battery/source/render_stl_previews.py
+127
View File
@@ -0,0 +1,127 @@
"""Render six inspection views of an STL using Blender.
Usage:
blender --background --python tools/render_stl_previews.py -- \
input.stl output-directory basename [comma-separated-views]
"""
import os
import sys
import bpy
from mathutils import Vector
def arguments():
args = sys.argv[sys.argv.index("--") + 1 :]
if len(args) not in (3, 4):
raise SystemExit(
"expected: input.stl output-directory basename [comma-separated-views]"
)
requested_views = args[3].split(",") if len(args) == 4 else None
return args[0], args[1], args[2], requested_views
def look_at(camera, target):
direction = Vector(target) - camera.location
camera.rotation_euler = direction.to_track_quat("-Z", "Y").to_euler()
def render_view(camera, center, span, name, direction, output_dir, basename):
distance = span * 2.2
camera.location = Vector(center) + Vector(direction).normalized() * distance
look_at(camera, center)
camera.data.type = "ORTHO"
camera.data.ortho_scale = span * 1.35
bpy.context.scene.render.filepath = os.path.join(
output_dir, f"{basename}_{name}.png"
)
bpy.ops.render.render(write_still=True)
def main():
input_path, output_dir, basename, requested_views = arguments()
os.makedirs(output_dir, exist_ok=True)
bpy.ops.wm.read_factory_settings(use_empty=True)
bpy.ops.wm.stl_import(filepath=os.path.abspath(input_path))
model = bpy.context.selected_objects[0]
model.name = "Feather case"
material = bpy.data.materials.new("Case material")
material.diffuse_color = (0.16, 0.42, 0.72, 1.0)
material.metallic = 0.0
material.roughness = 0.45
model.data.materials.append(material)
corners = [model.matrix_world @ Vector(corner) for corner in model.bound_box]
mins = Vector([min(v[i] for v in corners) for i in range(3)])
maxs = Vector([max(v[i] for v in corners) for i in range(3)])
center = (mins + maxs) / 2
span = max(maxs - mins)
world = bpy.data.worlds.new("Inspection world")
world.use_nodes = True
world.node_tree.nodes["Background"].inputs["Color"].default_value = (
0.035,
0.04,
0.05,
1,
)
world.node_tree.nodes["Background"].inputs["Strength"].default_value = 0.5
bpy.context.scene.world = world
camera_data = bpy.data.cameras.new("Camera")
camera = bpy.data.objects.new("Camera", camera_data)
bpy.context.collection.objects.link(camera)
bpy.context.scene.camera = camera
key_data = bpy.data.lights.new("Key", type="AREA")
key_data.energy = 900
key_data.shape = "DISK"
key_data.size = span
key = bpy.data.objects.new("Key", key_data)
key.location = center + Vector((span, -span, span * 1.5))
bpy.context.collection.objects.link(key)
fill_data = bpy.data.lights.new("Fill", type="AREA")
fill_data.energy = 500
fill_data.size = span
fill = bpy.data.objects.new("Fill", fill_data)
fill.location = center + Vector((-span, span, span))
bpy.context.collection.objects.link(fill)
scene = bpy.context.scene
scene.render.engine = "BLENDER_WORKBENCH"
scene.render.resolution_x = 800
scene.render.resolution_y = 600
scene.render.resolution_percentage = 100
scene.render.image_settings.file_format = "PNG"
scene.render.film_transparent = False
scene.display.shading.light = "STUDIO"
scene.display.shading.color_type = "MATERIAL"
scene.display.shading.show_shadows = True
scene.display.shading.show_cavity = True
scene.display.shading.cavity_type = "BOTH"
scene.display.shading.curvature_ridge_factor = 1.5
scene.display.shading.curvature_valley_factor = 1.2
views = {
"iso": (1, -1, 0.8),
"front": (-1, 0, 0),
"back": (1, 0, 0),
"left": (0, -1, 0),
"right": (0, 1, 0),
"top": (0, 0, 1),
}
selected = requested_views or list(views)
unknown = sorted(set(selected) - set(views))
if unknown:
raise SystemExit(f"unknown views: {', '.join(unknown)}")
for name in selected:
direction = views[name]
render_view(camera, center, span, name, direction, output_dir, basename)
if __name__ == "__main__":
main()
cases/attitude-imu/README.md
+25
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# Attitude IMU
Generated by the Feather Case Wizard.
- Top profile: `generic`
- FeatherWings: 1
- Battery compartment: no
- 1/4-20 insert: yes
- Approximate exterior: 60.8 × 41.7 × 35.8 mm
- Formats: 3mf
- Parts: `body`, `lid`
- Custom cutouts: 0
Run `ruby build.rb` in this directory to regenerate exports and previews.
OpenSCAD and Blender must be installed. Set `OPENSCAD` or `BLENDER` to
override their executable paths.
To open the saved Customizer values manually:
```bash
openscad -p parameters.json -P attitude-imu source/feather_case.scad
```
The 3MF files contain portable geometry only. Choose printer, filament,
plate, and slicing settings in Bambu Studio.
cases/attitude-imu/build.rb
Executable
+123
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#!/usr/bin/env ruby
# frozen_string_literal: true
require "fileutils"
require "json"
require "open3"
require "pathname"
require "tmpdir"
require "yaml"
ROOT = Pathname(__dir__).expand_path
def executable(env_name, command)
override = ENV[env_name]
return File.expand_path(override) if override && File.executable?(override)
ENV.fetch("PATH", "").split(File::PATH_SEPARATOR).each do |directory|
candidate = File.join(directory, command)
return candidate if File.file?(candidate) && File.executable?(candidate)
end
nil
end
def literal(value)
case value
when String then JSON.generate(value)
when TrueClass then "true"
when FalseClass then "false"
when Numeric then value.to_s
when Array then "[#{value.map { |item| literal(item) }.join(",")}]"
else raise "Cannot convert #{value.inspect} to OpenSCAD"
end
end
def run!(*command, env: {})
stdout, stderr, status = Open3.capture3(env, *command)
return if status.success?
warn [stdout, stderr].reject(&:empty?).join("\n")
raise "Command failed (#{status.exitstatus}): #{command.first}"
end
config = YAML.safe_load_file(ROOT.join("case.yml"), permitted_classes: [],
permitted_symbols: [], aliases: false)
openscad = executable("OPENSCAD", "openscad")
blender = executable("BLENDER", "blender")
abort "OpenSCAD not found; install it or set OPENSCAD" unless openscad
abort "Blender not found; install it or set BLENDER" unless blender
parameters = config.fetch("parameters").merge(
"extra_cutouts" => config.fetch("resolved").fetch("extra_cutouts")
)
parts = %w[body lid] + config.fetch("outputs").fetch("coupons")
buttons = %w[button_a button_b button_c button_reset]
if parameters["top_profile"] == "oled128x64" &&
buttons.any? { |name| parameters[name] }
parts << "buttons"
end
stage = Pathname(Dir.mktmpdir(".rebuild-", ROOT.to_s))
begin
exports = stage.join("exports")
previews = stage.join("previews")
scratch = stage.join("meshes")
FileUtils.mkdir_p([exports, previews, scratch])
model = ROOT.join("source/feather_case.scad")
renderer = ROOT.join("source/render_stl_previews.py")
export = lambda do |output, part, overrides = {}|
values = parameters.merge(overrides).merge("part" => part)
command = [openscad, "-o", output.to_s]
values.each { |name, value| command.concat(["-D", "#{name}=#{literal(value)}"]) }
run!(*command, model.to_s)
end
config.fetch("outputs").fetch("formats").each do |format|
directory = exports.join(format)
FileUtils.mkdir_p(directory)
parts.each do |part|
puts "Exporting #{part}.#{format}…"
export.call(directory.join("#{part}.#{format}"), part)
end
end
assembly = scratch.join("assembly.stl")
puts "Preparing assembly preview…"
export.call(assembly, "assembly",
"exploded_view" => config.fetch("outputs").fetch("assembly_exploded_view"),
"show_references" => false)
render_env = {"DISPLAY" => nil, "WAYLAND_DISPLAY" => nil}
run!(blender, "--background", "-noaudio", "--python", renderer.to_s, "--",
assembly.to_s, previews.to_s, "assembly", env: render_env)
parts.each do |part|
puts "Rendering #{part} preview…"
mesh = scratch.join("#{part}.stl")
export.call(mesh, part) unless mesh.file?
run!(blender, "--background", "-noaudio", "--python", renderer.to_s, "--",
mesh.to_s, previews.to_s, part, "iso", env: render_env)
end
backup = ROOT.join(".build-old-#{Process.pid}")
FileUtils.mkdir_p(backup)
%w[exports previews].each do |name|
current = ROOT.join(name)
FileUtils.mv(current, backup.join(name)) if current.exist?
end
begin
FileUtils.mv(exports, ROOT.join("exports"))
FileUtils.mv(previews, ROOT.join("previews"))
FileUtils.rm_rf(backup)
rescue StandardError
FileUtils.rm_rf(ROOT.join("exports"))
FileUtils.rm_rf(ROOT.join("previews"))
%w[exports previews].each do |name|
saved = backup.join(name)
FileUtils.mv(saved, ROOT.join(name)) if saved.exist?
end
raise
end
puts "Rebuilt #{ROOT}"
ensure
FileUtils.rm_rf(stage)
end
cases/attitude-imu/case.yml
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---
schema_version: 1
name: Attitude IMU
slug: attitude-imu
generator:
sha256: be611e3255e7d802719ebb0628e3d11481f8de05fc96c24d452f026d7b8e3353
created_with: feather-case-wizard
parameters:
top_profile: generic
wing_count: 1
wing_pitch: 12.25
stack_height_override: 0.0
generic_component_height: 3.0
generic_top_gap: 2.0
gps_antenna_height: 6.0
gps_top_gap: 5.0
oled_component_height: 2.4
oled_display_height: 1.5
oled_face_gap: 0.8
button_a: true
button_b: true
button_c: true
button_reset: false
button_projection: 1.5
button_cap_size:
- 5.0
- 3.2
button_flange_size:
- 6.6
- 3.6
button_flange_thickness: 0.9
button_travel: 0.5
button_contact_extension: 0.7
battery_enabled: false
battery_length: 69.0
battery_diameter: 18.0
battery_radial_clearance: 0.6
battery_end_clearance: 1.0
switch_hole_diameter: 12.0
switch_hole_compensation: 0.3
switch_cap_diameter: 8.0
switch_flange_diameter: 16.2
switch_body_length: 24.0
switch_body_diameter: 12.0
switch_wire_allowance: 3.0
tripod_insert_enabled: true
tripod_insert_length: 6.4
tripod_insert_hole_diameter: 8.8
tripod_thread_clearance_diameter: 6.8
tripod_boss_diameter: 14.0
m25_insert_length: 4.0
m25_insert_hole_diameter: 3.7
m25_screw_clearance: 2.8
m25_boss_diameter: 7.0
insert_entry_chamfer: 0.6
insert_melt_relief: 0.8
wall_thickness: 2.4
floor_thickness: 2.4
lid_thickness: 3.2
corner_radius: 4.0
board_bottom_clearance: 5.4
board_side_clearance: 7.0
board_rear_clearance: 4.0
usb_board_wall_gap: 1.2
lid_lip_depth: 2.4
lid_lip_thickness: 1.2
fit_clearance: 0.35
hole_compensation: 0.2
lid_screw_head_diameter: 5.2
lid_screw_head_height: 2.5
usb_opening_width: 12.5
usb_opening_height: 7.0
usb_opening_radius: 1.5
usb_vertical_offset: 0.0
cutouts: []
outputs:
formats:
- 3mf
coupons: []
assembly_exploded_view: 8
resolved:
extra_cutouts: []
cases/attitude-imu/parameters.json
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{
"parameterSets": {
"attitude-imu": {
"top_profile": "\"generic\"",
"wing_count": "1",
"wing_pitch": "12.25",
"stack_height_override": "0.0",
"generic_component_height": "3.0",
"generic_top_gap": "2.0",
"gps_antenna_height": "6.0",
"gps_top_gap": "5.0",
"oled_component_height": "2.4",
"oled_display_height": "1.5",
"oled_face_gap": "0.8",
"button_a": "true",
"button_b": "true",
"button_c": "true",
"button_reset": "false",
"button_projection": "1.5",
"button_cap_size": "[5.0,3.2]",
"button_flange_size": "[6.6,3.6]",
"button_flange_thickness": "0.9",
"button_travel": "0.5",
"button_contact_extension": "0.7",
"battery_enabled": "false",
"battery_length": "69.0",
"battery_diameter": "18.0",
"battery_radial_clearance": "0.6",
"battery_end_clearance": "1.0",
"switch_hole_diameter": "12.0",
"switch_hole_compensation": "0.3",
"switch_cap_diameter": "8.0",
"switch_flange_diameter": "16.2",
"switch_body_length": "24.0",
"switch_body_diameter": "12.0",
"switch_wire_allowance": "3.0",
"tripod_insert_enabled": "true",
"tripod_insert_length": "6.4",
"tripod_insert_hole_diameter": "8.8",
"tripod_thread_clearance_diameter": "6.8",
"tripod_boss_diameter": "14.0",
"m25_insert_length": "4.0",
"m25_insert_hole_diameter": "3.7",
"m25_screw_clearance": "2.8",
"m25_boss_diameter": "7.0",
"insert_entry_chamfer": "0.6",
"insert_melt_relief": "0.8",
"wall_thickness": "2.4",
"floor_thickness": "2.4",
"lid_thickness": "3.2",
"corner_radius": "4.0",
"board_bottom_clearance": "5.4",
"board_side_clearance": "7.0",
"board_rear_clearance": "4.0",
"usb_board_wall_gap": "1.2",
"lid_lip_depth": "2.4",
"lid_lip_thickness": "1.2",
"fit_clearance": "0.35",
"hole_compensation": "0.2",
"lid_screw_head_diameter": "5.2",
"lid_screw_head_height": "2.5",
"usb_opening_width": "12.5",
"usb_opening_height": "7.0",
"usb_opening_radius": "1.5",
"usb_vertical_offset": "0.0"
}
},
"fileFormatVersion": "1"
}
cases/attitude-imu/source/feather_case.scad
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/*
* Parametric enclosure for the Adafruit ESP32 Feather V2 and FeatherWings.
*
* Coordinate system:
* X: USB-C wall (0) toward the rear of the case
* Y: non-battery side (0) toward the battery/JST side
* Z: outside bottom (0) upward
*
* Board coordinates are derived from Adafruit's Eagle PCB files:
* https://github.com/adafruit/Adafruit-ESP32-Feather-V2-PCB
* https://github.com/adafruit/Adafruit-OLED-FeatherWing-PCB
*/
/* [Output] */
part = "assembly"; // [assembly,body,lid,buttons,insert_coupon,switch_coupon,fit_coupon]
exploded_view = 8; // [0:1:20]
show_references = true;
/* [Stack] */
top_profile = "generic"; // [generic,gps,oled128x64]
wing_count = 1; // [1:1:8]
wing_pitch = 12.25; // [7:0.1:16]
stack_height_override = 0; // [0:0.1:100]
generic_component_height = 3; // [0:0.1:30]
generic_top_gap = 2; // [0.5:0.1:10]
gps_antenna_height = 6;
gps_top_gap = 5;
oled_component_height = 2.4;
oled_display_height = 1.5;
oled_face_gap = 0.8;
/* [OLED controls] */
button_a = true;
button_b = true;
button_c = true;
button_reset = false;
button_projection = 1.5; // [0.5:0.1:3]
button_cap_size = [5, 3.2];
button_flange_size = [6.6, 3.6];
button_flange_thickness = 0.9;
button_travel = 0.5;
button_contact_extension = 0.7;
/* [Battery and switch] */
battery_enabled = false;
battery_length = 69;
battery_diameter = 18;
battery_radial_clearance = 0.6;
battery_end_clearance = 1;
switch_hole_diameter = 12;
switch_hole_compensation = 0.3;
switch_cap_diameter = 8;
switch_flange_diameter = 16.2;
switch_body_length = 24;
switch_body_diameter = 12;
switch_wire_allowance = 3;
/* [Tripod mount] */
tripod_insert_enabled = false;
tripod_insert_length = 6.4;
tripod_insert_hole_diameter = 8.8;
tripod_thread_clearance_diameter = 6.8;
tripod_boss_diameter = 14;
/* [M2.5 inserts] */
m25_insert_length = 4;
m25_insert_hole_diameter = 3.7;
m25_screw_clearance = 2.8;
m25_boss_diameter = 7;
insert_entry_chamfer = 0.6;
insert_melt_relief = 0.8;
/* [Shell and fit] */
wall_thickness = 2.4;
floor_thickness = 2.4;
lid_thickness = 3.2;
corner_radius = 4;
board_bottom_clearance = 5.4;
board_side_clearance = 7;
board_rear_clearance = 4;
usb_board_wall_gap = 1.2;
lid_lip_depth = 2.4;
lid_lip_thickness = 1.2;
fit_clearance = 0.35;
hole_compensation = 0.2;
lid_screw_head_diameter = 5.2;
lid_screw_head_height = 2.5;
/* [USB-C opening] */
usb_opening_width = 12.5;
usb_opening_height = 7;
usb_opening_radius = 1.5;
usb_vertical_offset = 0;
/* [Custom wall cutouts] */
// Entry format: [face, shape, u, z, width, height, radius]
// face: front, rear, left, right. u is Y on front/rear and X on left/right.
// shape: circle, rect, roundrect, slot. Circle uses width as its diameter.
extra_cutouts = [];
/* [Calibration] */
coupon_steps = [-0.3, -0.15, 0, 0.15, 0.3];
$fn = $preview ? 36 : 72;
eps = 0.02;
// Adafruit Feather mechanical reference, millimetres.
feather_length = 50.8;
feather_width = 22.86;
board_thickness = 1.6;
mount_x = [2.54, 48.26];
mount_y = [2.54, 20.32];
usb_center_y = 11.43;
// Official 128x64 OLED FeatherWing geometry in Feather-board coordinates.
oled_visible_min = [11.42, 3.78];
oled_visible_size = [30, 15.3];
oled_button_a_xy = [4.318, 15.875];
oled_button_b_xy = [4.318, 11.43];
oled_button_c_xy = [4.318, 6.985];
oled_button_reset_xy = [7.366, 20.828];
effective_floor = tripod_insert_enabled
? max(floor_thickness, tripod_insert_length + insert_melt_relief + 1.2)
: floor_thickness;
effective_board_clearance = max(
board_bottom_clearance,
m25_insert_length + insert_melt_relief + 0.6
);
board_origin_x = wall_thickness + usb_board_wall_gap;
board_origin_y = wall_thickness + board_side_clearance;
board_bottom_z = effective_floor + effective_board_clearance;
board_top_z = board_bottom_z + board_thickness;
computed_top_pcb_z = board_top_z + wing_count * wing_pitch;
top_pcb_z = stack_height_override > 0
? board_top_z + stack_height_override
: computed_top_pcb_z;
profile_component_height =
top_profile == "gps" ? gps_antenna_height :
top_profile == "oled128x64" ? oled_component_height :
generic_component_height;
profile_top_gap =
top_profile == "gps" ? gps_top_gap :
top_profile == "oled128x64" ? oled_face_gap :
generic_top_gap;
partition_y = board_origin_y + feather_width + 1;
battery_center_y = partition_y + wall_thickness + battery_radial_clearance
+ battery_diameter / 2;
battery_start_x = board_origin_x + battery_end_clearance;
battery_end_x = battery_start_x + battery_length;
switch_center_x = battery_end_x + max(
switch_body_diameter / 2 + 0.8,
switch_flange_diameter / 2 + 0.5
);
case_length_plain = board_origin_x + feather_length
+ board_rear_clearance + wall_thickness;
case_length_battery = switch_center_x + switch_flange_diameter / 2
+ 1.2 + wall_thickness;
case_length = battery_enabled ? max(case_length_plain, case_length_battery)
: case_length_plain;
case_width_plain = board_origin_y + feather_width
+ board_side_clearance + wall_thickness;
case_width_battery = battery_center_y + battery_diameter / 2
+ battery_radial_clearance + wall_thickness;
case_width = battery_enabled ? max(case_width_plain, case_width_battery)
: case_width_plain;
battery_center_z = effective_floor + battery_radial_clearance
+ battery_diameter / 2;
switch_center_z = max(
effective_floor + switch_flange_diameter / 2 + 1,
battery_center_z
);
electronics_ceiling_z = top_pcb_z + profile_component_height + profile_top_gap;
battery_ceiling_z = battery_enabled
? max(
battery_center_z + battery_diameter / 2 + battery_radial_clearance,
switch_center_z + switch_flange_diameter / 2 + 1
)
: 0;
body_height = max(electronics_ceiling_z, battery_ceiling_z);
lid_boss_r = m25_boss_diameter / 2;
lid_boss_wall_overlap = 0.6;
lid_boss_xy = [
[
wall_thickness + lid_boss_r - lid_boss_wall_overlap,
wall_thickness + lid_boss_r - lid_boss_wall_overlap
],
[
case_length - wall_thickness - lid_boss_r + lid_boss_wall_overlap,
wall_thickness + lid_boss_r - lid_boss_wall_overlap
],
[
wall_thickness + lid_boss_r - lid_boss_wall_overlap,
case_width - wall_thickness - lid_boss_r + lid_boss_wall_overlap
],
[
case_length - wall_thickness - lid_boss_r + lid_boss_wall_overlap,
case_width - wall_thickness - lid_boss_r + lid_boss_wall_overlap
]
];
assert(wing_count >= 1, "wing_count must be at least one");
assert(top_profile == "generic" || top_profile == "gps"
|| top_profile == "oled128x64", "Unsupported top_profile");
assert(wall_thickness >= 1.2, "wall_thickness is too small for 0.6 mm FDM");
assert(lid_lip_thickness >= 1.2, "lid lip needs at least two 0.6 mm lines");
assert(m25_boss_diameter > m25_insert_hole_diameter + 2,
"M2.5 boss does not have enough radial material");
assert(!tripod_insert_enabled
|| tripod_boss_diameter > tripod_insert_hole_diameter + 3,
"Tripod insert boss does not have enough radial material");
function clamp(v, lo, hi) = min(max(v, lo), hi);
module rounded_rect_2d(size, radius) {
r = clamp(radius, 0.01, min(size[0], size[1]) / 2 - 0.01);
hull() {
for (x = [r, size[0] - r], y = [r, size[1] - r])
translate([x, y]) circle(r = r);
}
}
module centered_rounded_rect_2d(size, radius) {
translate([-size[0] / 2, -size[1] / 2])
rounded_rect_2d(size, radius);
}
module centered_rounded_prism(size, height, radius) {
linear_extrude(height = height)
centered_rounded_rect_2d(size, radius);
}
module rounded_box(size, radius) {
linear_extrude(height = size[2])
rounded_rect_2d([size[0], size[1]], radius);
}
module insert_pocket(diameter, depth, entry_z, downward = true) {
bore_d = diameter + hole_compensation;
if (downward) {
translate([0, 0, entry_z - depth])
cylinder(h = depth + eps, d = bore_d);
translate([0, 0, entry_z - insert_entry_chamfer])
cylinder(
h = insert_entry_chamfer + eps,
d1 = bore_d,
d2 = bore_d + 2 * insert_entry_chamfer
);
} else {
translate([0, 0, entry_z - eps])
cylinder(h = depth + eps, d = bore_d);
translate([0, 0, entry_z - eps])
cylinder(
h = insert_entry_chamfer + eps,
d1 = bore_d + 2 * insert_entry_chamfer,
d2 = bore_d
);
}
}
module face_rounded_cutout(face, u, z, width, height, radius) {
r = clamp(radius, 0.01, min(width, height) / 2);
depth = wall_thickness + 2 * eps;
if (face == "front" || face == "rear") {
x0 = face == "front" ? -eps : case_length - wall_thickness - eps;
hull()
for (yy = [u - width / 2 + r, u + width / 2 - r],
zz = [z - height / 2 + r, z + height / 2 - r])
translate([x0, yy, zz])
rotate([0, 90, 0]) cylinder(h = depth, r = r);
} else if (face == "left" || face == "right") {
y0 = face == "left" ? -eps : case_width - wall_thickness - eps;
hull()
for (xx = [u - width / 2 + r, u + width / 2 - r],
zz = [z - height / 2 + r, z + height / 2 - r])
translate([xx, y0, zz])
rotate([-90, 0, 0]) cylinder(h = depth, r = r);
}
}
module face_circle_cutout(face, u, z, diameter) {
depth = wall_thickness + 2 * eps;
if (face == "front")
translate([-eps, u, z])
rotate([0, 90, 0]) cylinder(h = depth, d = diameter);
else if (face == "rear")
translate([case_length - wall_thickness - eps, u, z])
rotate([0, 90, 0]) cylinder(h = depth, d = diameter);
else if (face == "left")
translate([u, -eps, z])
rotate([-90, 0, 0]) cylinder(h = depth, d = diameter);
else if (face == "right")
translate([u, case_width - wall_thickness - eps, z])
rotate([-90, 0, 0]) cylinder(h = depth, d = diameter);
}
module custom_wall_cutout(entry) {
face = entry[0];
shape = entry[1];
u = entry[2];
z = entry[3];
width = entry[4];
height = len(entry) > 5 ? entry[5] : width;
radius = len(entry) > 6 ? entry[6] : min(width, height) / 2;
assert(face == "front" || face == "rear"
|| face == "left" || face == "right", "Invalid cutout face");
assert(shape == "circle" || shape == "rect"
|| shape == "roundrect" || shape == "slot", "Invalid cutout shape");
assert(z - height / 2 >= effective_floor,
"Cutout intersects the floor");
assert(z + height / 2 <= body_height - lid_lip_depth,
"Cutout intersects the lid locating lip");
assert(
(face == "front" || face == "rear")
? u - width / 2 >= 0 && u + width / 2 <= case_width
: u - width / 2 >= 0 && u + width / 2 <= case_length,
"Cutout extends beyond its wall"
);
if (shape == "circle")
face_circle_cutout(face, u, z, width);
else
face_rounded_cutout(
face, u, z, width, height,
shape == "rect" ? 0.02 :
shape == "slot" ? min(width, height) / 2 : radius
);
}
module board_standoffs() {
for (mx = mount_x, my = mount_y)
translate([
board_origin_x + mx,
board_origin_y + my,
effective_floor - eps
])
cylinder(
h = effective_board_clearance + eps,
d = m25_boss_diameter
);
}
module lid_bosses() {
for (p = lid_boss_xy)
translate([p[0], p[1], effective_floor - eps])
cylinder(
h = body_height - effective_floor + eps,
d = m25_boss_diameter
);
}
module battery_cradle() {
partition_height = min(
body_height - lid_lip_depth - 0.5,
battery_center_z + battery_diameter / 2 + 1.5
);
rib_width = 2.4;
rib_positions = [
battery_start_x + 4,
(battery_start_x + battery_end_x) / 2,
battery_end_x - 4
];
// Board/battery partition, with a lead-routing notch near the JST end.
difference() {
translate([wall_thickness, partition_y, effective_floor - eps])
cube([
battery_end_x - wall_thickness + battery_end_clearance,
wall_thickness,
partition_height - effective_floor + eps
]);
translate([
board_origin_x + 6.5,
partition_y - eps,
effective_floor + 1.5
])
cube([9, wall_thickness + 2 * eps, 6]);
}
// Three low curved ribs cradle the protected cylindrical pack.
for (x = rib_positions)
difference() {
translate([
x - rib_width / 2,
battery_center_y - battery_diameter / 2
- battery_radial_clearance,
effective_floor - eps
])
cube([
rib_width,
battery_diameter + 2 * battery_radial_clearance,
battery_diameter / 2 + battery_radial_clearance + eps
]);
translate([x - rib_width, battery_center_y, battery_center_z])
rotate([0, 90, 0])
cylinder(
h = rib_width * 2,
d = battery_diameter + 2 * battery_radial_clearance
);
}
// End stops remain below the cell center so the lid can remove vertically.
for (x = [
battery_start_x - battery_end_clearance - wall_thickness,
battery_end_x + battery_end_clearance
])
translate([
x,
battery_center_y - battery_diameter / 2 - battery_radial_clearance,
effective_floor - eps
])
cube([
wall_thickness,
battery_diameter + 2 * battery_radial_clearance,
battery_diameter / 2 + 1 + eps
]);
// Rear cross-strip separates the side-mounted switch body from the cell.
translate([
battery_end_x + battery_end_clearance,
partition_y,
effective_floor - eps
])
cube([
case_length - wall_thickness - battery_end_x - battery_end_clearance,
case_width - wall_thickness - partition_y,
min(body_height - effective_floor, switch_center_z
+ switch_body_diameter / 2 + switch_wire_allowance
- effective_floor) + eps
]);
}
module body_positive() {
union() {
difference() {
rounded_box([case_length, case_width, body_height], corner_radius);
translate([wall_thickness, wall_thickness, effective_floor])
rounded_box([
case_length - 2 * wall_thickness,
case_width - 2 * wall_thickness,
body_height - effective_floor + eps
], max(0.6, corner_radius - wall_thickness));
}
board_standoffs();
lid_bosses();
if (battery_enabled)
battery_cradle();
if (tripod_insert_enabled)
translate([case_length / 2, case_width / 2, 0])
cylinder(h = effective_floor, d = tripod_boss_diameter);
}
}
module body_cutouts() {
// Board mounting insert pockets, loaded from above before the Feather.
for (mx = mount_x, my = mount_y)
translate([board_origin_x + mx, board_origin_y + my, 0])
insert_pocket(
m25_insert_hole_diameter,
m25_insert_length + insert_melt_relief,
board_bottom_z
);
// Lid insert pockets, loaded from the top of the body.
for (p = lid_boss_xy)
translate([p[0], p[1], 0])
insert_pocket(
m25_insert_hole_diameter,
m25_insert_length + insert_melt_relief,
body_height
);
// USB-C cable opening. Connector center is from the official ESP32 V2 PCB.
usb_center_z = board_top_z + 1.6 + usb_vertical_offset;
face_rounded_cutout(
"front",
board_origin_y + usb_center_y,
usb_center_z,
usb_opening_width + hole_compensation,
usb_opening_height + hole_compensation,
usb_opening_radius
);
if (battery_enabled) {
face_circle_cutout(
"right",
switch_center_x,
switch_center_z,
switch_hole_diameter + switch_hole_compensation
);
// Clear the switch body and its prewired terminals through the rear bay.
translate([
switch_center_x,
case_width - wall_thickness + eps,
switch_center_z
])
rotate([90, 0, 0])
cylinder(
h = switch_body_length + switch_wire_allowance
+ wall_thickness + eps,
d = switch_body_diameter + 2 * fit_clearance
);
}
if (tripod_insert_enabled) {
translate([case_length / 2, case_width / 2, 0]) {
translate([0, 0, -eps])
cylinder(
h = effective_floor + 2 * eps,
d = tripod_thread_clearance_diameter + hole_compensation
);
insert_pocket(
tripod_insert_hole_diameter,
tripod_insert_length + insert_melt_relief,
effective_floor
);
}
}
for (entry = extra_cutouts)
custom_wall_cutout(entry);
}
module body() {
difference() {
body_positive();
body_cutouts();
}
}
module lid_plate_positive() {
union() {
rounded_box([case_length, case_width, lid_thickness], corner_radius);
// Inset rim: exported pointing upward so the outer lid face prints flat.
translate([
wall_thickness + fit_clearance,
wall_thickness + fit_clearance,
lid_thickness
])
linear_extrude(height = lid_lip_depth)
difference() {
rounded_rect_2d([
case_length - 2 * (wall_thickness + fit_clearance),
case_width - 2 * (wall_thickness + fit_clearance)
], max(0.6, corner_radius - wall_thickness));
translate([lid_lip_thickness, lid_lip_thickness])
rounded_rect_2d([
case_length - 2 * (
wall_thickness + fit_clearance
+ lid_lip_thickness
),
case_width - 2 * (
wall_thickness + fit_clearance
+ lid_lip_thickness
)
], max(0.5, corner_radius - wall_thickness
- lid_lip_thickness));
}
}
}
module beveled_oled_window() {
inner_size = oled_visible_size;
outer_size = [oled_visible_size[0] + 3, oled_visible_size[1] + 3];
center = [
board_origin_x + oled_visible_min[0] + oled_visible_size[0] / 2,
board_origin_y + oled_visible_min[1] + oled_visible_size[1] / 2
];
hull() {
translate([center[0], center[1], -eps])
linear_extrude(height = eps)
centered_rounded_rect_2d(outer_size, 1.5);
translate([center[0], center[1], lid_thickness - eps])
linear_extrude(height = 2 * eps)
centered_rounded_rect_2d(inner_size, 0.8);
}
}
module oled_button_lid_cutout(xy) {
center = [board_origin_x + xy[0], board_origin_y + xy[1]];
shaft_size = [
button_cap_size[0] + fit_clearance * 2,
button_cap_size[1] + fit_clearance * 2
];
recess_size = [
button_flange_size[0] + fit_clearance * 2,
button_flange_size[1] + fit_clearance * 2
];
recess_depth = button_flange_thickness + button_travel;
translate([center[0], center[1], -eps])
centered_rounded_prism(
shaft_size,
lid_thickness + 2 * eps,
shaft_size[1] / 2
);
translate([center[0], center[1], lid_thickness - recess_depth])
centered_rounded_prism(
recess_size,
recess_depth + lid_lip_depth + eps,
recess_size[1] / 2
);
}
module lid_cutouts() {
// Through holes plus shallow counterbores for flush M2.5 socket heads.
for (p = lid_boss_xy) {
translate([p[0], p[1], -eps])
cylinder(
h = lid_thickness + lid_lip_depth + 2 * eps,
d = m25_screw_clearance + hole_compensation
);
translate([p[0], p[1], -eps])
cylinder(
h = lid_screw_head_height + eps,
d = lid_screw_head_diameter + hole_compensation
);
}
if (top_profile == "oled128x64") {
beveled_oled_window();
if (button_a) oled_button_lid_cutout(oled_button_a_xy);
if (button_b) oled_button_lid_cutout(oled_button_b_xy);
if (button_c) oled_button_lid_cutout(oled_button_c_xy);
if (button_reset) oled_button_lid_cutout(oled_button_reset_xy);
}
}
module lid() {
difference() {
lid_plate_positive();
lid_cutouts();
}
}
module one_oled_button() {
recess_depth = button_flange_thickness + button_travel;
stem_height = lid_thickness - recess_depth + button_projection;
// Print outer cap face down. The flange and contact nub build upward.
centered_rounded_prism(
button_cap_size,
stem_height,
button_cap_size[1] / 2
);
translate([0, 0, stem_height])
centered_rounded_prism(
button_flange_size,
button_flange_thickness,
button_flange_size[1] / 2
);
translate([0, 0, stem_height + button_flange_thickness])
cylinder(h = button_contact_extension, d = 3);
}
module buttons() {
enabled = [
button_a,
button_b,
button_c,
button_reset
];
count_enabled = len([for (v = enabled) if (v) 1]);
if (count_enabled == 0)
echo("No OLED buttons are enabled.");
for (i = [0 : len(enabled) - 1])
if (enabled[i])
translate([i * (button_flange_size[0] + 3), 0, 0])
one_oled_button();
}
module reference_board() {
color([0.05, 0.25, 0.55, 0.75])
translate([board_origin_x, board_origin_y, board_bottom_z])
rounded_box([feather_length, feather_width, board_thickness], 2.54);
color([0.12, 0.45, 0.75, 0.45])
for (i = [1 : wing_count])
translate([
board_origin_x,
board_origin_y,
board_top_z + i * wing_pitch - board_thickness
])
rounded_box(
[feather_length, feather_width, board_thickness], 2.54
);
}
module reference_top_feature() {
if (top_profile == "gps")
color([0.92, 0.78, 0.35, 0.8])
translate([
board_origin_x + 31,
board_origin_y + (feather_width - 15) / 2,
top_pcb_z
])
cube([15, 15, gps_antenna_height]);
else if (top_profile == "oled128x64") {
color([0.12, 0.12, 0.12, 0.9])
translate([
board_origin_x + oled_visible_min[0],
board_origin_y + oled_visible_min[1],
top_pcb_z
])
cube([
oled_visible_size[0],
oled_visible_size[1],
oled_display_height
]);
color([0.6, 0.6, 0.6, 0.9])
for (xy = [
oled_button_a_xy,
oled_button_b_xy,
oled_button_c_xy,
oled_button_reset_xy
])
translate([
board_origin_x + xy[0],
board_origin_y + xy[1],
top_pcb_z
])
cylinder(h = 1.6, d = 2.1);
} else
color([0.3, 0.65, 0.35, 0.6])
translate([
board_origin_x + 10,
board_origin_y + 4,
top_pcb_z
])
cube([
feather_length - 20,
feather_width - 8,
generic_component_height
]);
}
module reference_battery_and_switch() {
if (battery_enabled) {
color([0.35, 0.18, 0.55, 0.75])
translate([battery_start_x, battery_center_y, battery_center_z])
rotate([0, 90, 0])
cylinder(h = battery_length, d = battery_diameter);
color([0.8, 0.15, 0.1, 0.65])
translate([
switch_center_x,
case_width - wall_thickness,
switch_center_z
])
rotate([90, 0, 0]) {
cylinder(h = switch_body_length, d = switch_body_diameter);
translate([0, 0, -1.5])
cylinder(h = 1.5, d = switch_flange_diameter);
translate([0, 0, -3])
cylinder(h = 3, d = switch_cap_diameter);
}
}
}
module assembly() {
color([0.82, 0.84, 0.88, 1]) body();
if ($preview && show_references) {
reference_board();
reference_top_feature();
reference_battery_and_switch();
}
// Printable lid is mirrored into its installed orientation and exploded up.
color([0.92, 0.92, 0.95, 0.88])
translate([0, case_width, body_height + lid_thickness + exploded_view])
rotate([180, 0, 0])
lid();
}
module coupon_hole(x, y, diameter, depth) {
translate([x, y, -eps]) cylinder(h = depth + 2 * eps, d = diameter);
}
module insert_coupon() {
spacing = 15;
coupon_length = spacing * len(coupon_steps) + 8;
coupon_width = 32;
coupon_height = max(
m25_insert_length + insert_melt_relief + 1.2,
tripod_insert_length + insert_melt_relief + 1.2
);
difference() {
rounded_box([coupon_length, coupon_width, coupon_height], 3);
for (i = [0 : len(coupon_steps) - 1]) {
x = 7 + i * spacing;
coupon_hole(
x, 8,
m25_insert_hole_diameter + coupon_steps[i],
m25_insert_length + insert_melt_relief
);
coupon_hole(
x, 23,
tripod_insert_hole_diameter + coupon_steps[i],
tripod_insert_length + insert_melt_relief
);
}
}
}
module switch_coupon() {
spacing = 18;
coupon_length = spacing * len(coupon_steps) + 6;
coupon_width = 24;
coupon_height = wall_thickness;
difference() {
rounded_box([coupon_length, coupon_width, coupon_height], 3);
for (i = [0 : len(coupon_steps) - 1])
translate([6 + i * spacing, coupon_width / 2, -eps])
cylinder(
h = coupon_height + 2 * eps,
d = switch_hole_diameter + coupon_steps[i]
);
}
}
module fit_coupon() {
segment_length = 34;
base_width = 16;
base_height = 6;
cavity_size = [segment_length - 8, base_width - 8];
male_size = [
cavity_size[0] - 2 * fit_clearance,
cavity_size[1] - 2 * fit_clearance
];
difference() {
rounded_box([segment_length, base_width, base_height], 2);
translate([4, 4, 2])
cube([segment_length - 8, base_width - 8, base_height]);
}
translate([segment_length + 5, 0, 0])
union() {
cube([segment_length, base_width, lid_thickness]);
translate([
4 + fit_clearance,
4 + fit_clearance,
lid_thickness - eps
])
linear_extrude(height = lid_lip_depth + eps)
difference() {
rounded_rect_2d(male_size, 1);
translate([lid_lip_thickness, lid_lip_thickness])
rounded_rect_2d([
male_size[0] - 2 * lid_lip_thickness,
male_size[1] - 2 * lid_lip_thickness
], 0.5);
}
}
}
if (part == "assembly")
assembly();
else if (part == "body")
body();
else if (part == "lid")
lid();
else if (part == "buttons")
buttons();
else if (part == "insert_coupon")
insert_coupon();
else if (part == "switch_coupon")
switch_coupon();
else if (part == "fit_coupon")
fit_coupon();
else
assert(false, str("Unknown part: ", part));
cases/attitude-imu/source/render_stl_previews.py
+127
View File
@@ -0,0 +1,127 @@
"""Render six inspection views of an STL using Blender.
Usage:
blender --background --python tools/render_stl_previews.py -- \
input.stl output-directory basename [comma-separated-views]
"""
import os
import sys
import bpy
from mathutils import Vector
def arguments():
args = sys.argv[sys.argv.index("--") + 1 :]
if len(args) not in (3, 4):
raise SystemExit(
"expected: input.stl output-directory basename [comma-separated-views]"
)
requested_views = args[3].split(",") if len(args) == 4 else None
return args[0], args[1], args[2], requested_views
def look_at(camera, target):
direction = Vector(target) - camera.location
camera.rotation_euler = direction.to_track_quat("-Z", "Y").to_euler()
def render_view(camera, center, span, name, direction, output_dir, basename):
distance = span * 2.2
camera.location = Vector(center) + Vector(direction).normalized() * distance
look_at(camera, center)
camera.data.type = "ORTHO"
camera.data.ortho_scale = span * 1.35
bpy.context.scene.render.filepath = os.path.join(
output_dir, f"{basename}_{name}.png"
)
bpy.ops.render.render(write_still=True)
def main():
input_path, output_dir, basename, requested_views = arguments()
os.makedirs(output_dir, exist_ok=True)
bpy.ops.wm.read_factory_settings(use_empty=True)
bpy.ops.wm.stl_import(filepath=os.path.abspath(input_path))
model = bpy.context.selected_objects[0]
model.name = "Feather case"
material = bpy.data.materials.new("Case material")
material.diffuse_color = (0.16, 0.42, 0.72, 1.0)
material.metallic = 0.0
material.roughness = 0.45
model.data.materials.append(material)
corners = [model.matrix_world @ Vector(corner) for corner in model.bound_box]
mins = Vector([min(v[i] for v in corners) for i in range(3)])
maxs = Vector([max(v[i] for v in corners) for i in range(3)])
center = (mins + maxs) / 2
span = max(maxs - mins)
world = bpy.data.worlds.new("Inspection world")
world.use_nodes = True
world.node_tree.nodes["Background"].inputs["Color"].default_value = (
0.035,
0.04,
0.05,
1,
)
world.node_tree.nodes["Background"].inputs["Strength"].default_value = 0.5
bpy.context.scene.world = world
camera_data = bpy.data.cameras.new("Camera")
camera = bpy.data.objects.new("Camera", camera_data)
bpy.context.collection.objects.link(camera)
bpy.context.scene.camera = camera
key_data = bpy.data.lights.new("Key", type="AREA")
key_data.energy = 900
key_data.shape = "DISK"
key_data.size = span
key = bpy.data.objects.new("Key", key_data)
key.location = center + Vector((span, -span, span * 1.5))
bpy.context.collection.objects.link(key)
fill_data = bpy.data.lights.new("Fill", type="AREA")
fill_data.energy = 500
fill_data.size = span
fill = bpy.data.objects.new("Fill", fill_data)
fill.location = center + Vector((-span, span, span))
bpy.context.collection.objects.link(fill)
scene = bpy.context.scene
scene.render.engine = "BLENDER_WORKBENCH"
scene.render.resolution_x = 800
scene.render.resolution_y = 600
scene.render.resolution_percentage = 100
scene.render.image_settings.file_format = "PNG"
scene.render.film_transparent = False
scene.display.shading.light = "STUDIO"
scene.display.shading.color_type = "MATERIAL"
scene.display.shading.show_shadows = True
scene.display.shading.show_cavity = True
scene.display.shading.cavity_type = "BOTH"
scene.display.shading.curvature_ridge_factor = 1.5
scene.display.shading.curvature_valley_factor = 1.2
views = {
"iso": (1, -1, 0.8),
"front": (-1, 0, 0),
"back": (1, 0, 0),
"left": (0, -1, 0),
"right": (0, 1, 0),
"top": (0, 0, 1),
}
selected = requested_views or list(views)
unknown = sorted(set(selected) - set(views))
if unknown:
raise SystemExit(f"unknown views: {', '.join(unknown)}")
for name in selected:
direction = views[name]
render_view(camera, center, span, name, direction, output_dir, basename)
if __name__ == "__main__":
main()
cases/gps/README.md
+2 -2
View File
@@ -6,9 +6,9 @@ Generated by the Feather Case Wizard.
- FeatherWings: 1
- Battery compartment: yes
- 1/4-20 insert: yes
- Approximate exterior: 93.9 × 57.3 × 38.6 mm
- Approximate exterior: 93.9 × 57.3 × 41.8 mm
- Formats: 3mf
- Parts: `body`, `lid`
- Parts: `body`, `lid`, `insert_coupon`, `switch_coupon`, `fit_coupon`
- Custom cutouts: 0
Run `ruby build.rb` in this directory to regenerate exports and previews.
cases/gps/case.yml
+9 -5
View File
@@ -3,18 +3,19 @@ schema_version: 1
name: GPS
slug: gps
generator:
sha256: a265164909faa0c364792224601af36381744a129b7cd7cbd6b6293815953f63
sha256: be611e3255e7d802719ebb0628e3d11481f8de05fc96c24d452f026d7b8e3353
created_with: feather-case-wizard
parameters:
top_profile: gps
wing_count: 1
wing_pitch: 11.0
stack_height_override: 0.0
wing_pitch: 12.25
stack_height_override: 12.25
generic_component_height: 3.0
generic_top_gap: 2.0
gps_antenna_height: 4.0
gps_antenna_height: 6.0
gps_top_gap: 5.0
oled_component_height: 2.4
oled_display_height: 1.5
oled_face_gap: 0.8
button_a: true
button_b: true
@@ -75,7 +76,10 @@ cutouts: []
outputs:
formats:
- 3mf
coupons: []
coupons:
- insert_coupon
- switch_coupon
- fit_coupon
assembly_exploded_view: 8
resolved:
extra_cutouts: []
cases/gps/parameters.json
+4 -3
View File
@@ -3,13 +3,14 @@
"gps": {
"top_profile": "\"gps\"",
"wing_count": "1",
"wing_pitch": "11.0",
"stack_height_override": "0.0",
"wing_pitch": "12.25",
"stack_height_override": "12.25",
"generic_component_height": "3.0",
"generic_top_gap": "2.0",
"gps_antenna_height": "4.0",
"gps_antenna_height": "6.0",
"gps_top_gap": "5.0",
"oled_component_height": "2.4",
"oled_display_height": "1.5",
"oled_face_gap": "0.8",
"button_a": "true",
"button_b": "true",
cases/gps/source/feather_case.scad
+4 -3
View File
@@ -19,13 +19,14 @@ show_references = true;
/* [Stack] */
top_profile = "generic"; // [generic,gps,oled128x64]
wing_count = 1; // [1:1:8]
wing_pitch = 11; // [7:0.1:16]
wing_pitch = 12.25; // [7:0.1:16]
stack_height_override = 0; // [0:0.1:100]
generic_component_height = 3; // [0:0.1:30]
generic_top_gap = 2; // [0.5:0.1:10]
gps_antenna_height = 4;
gps_antenna_height = 6;
gps_top_gap = 5;
oled_component_height = 2.4;
oled_display_height = 1.5;
oled_face_gap = 0.8;
/* [OLED controls] */
@@ -708,7 +709,7 @@ module reference_top_feature() {
cube([
oled_visible_size[0],
oled_visible_size[1],
oled_component_height
oled_display_height
]);
color([0.6, 0.6, 0.6, 0.9])
for (xy = [
cases/pan-tilt-head/README.md
+25
View File
@@ -0,0 +1,25 @@
# Pan/Tilt Head
Generated by the Feather Case Wizard.
- Top profile: `oled128x64`
- FeatherWings: 3
- Battery compartment: no
- 1/4-20 insert: yes
- Approximate exterior: 95.6 × 41.7 × 59.8 mm
- Formats: 3mf
- Parts: `body`, `lid`, `buttons`
- Custom cutouts: 4
Run `ruby build.rb` in this directory to regenerate exports and previews.
OpenSCAD and Blender must be installed. Set `OPENSCAD` or `BLENDER` to
override their executable paths.
To open the saved Customizer values manually:
```bash
openscad -p parameters.json -P pan-tilt-head source/feather_case.scad
```
The 3MF files contain portable geometry only. Choose printer, filament,
plate, and slicing settings in Bambu Studio.
cases/pan-tilt-head/build.rb
Executable
+123
View File
@@ -0,0 +1,123 @@
#!/usr/bin/env ruby
# frozen_string_literal: true
require "fileutils"
require "json"
require "open3"
require "pathname"
require "tmpdir"
require "yaml"
ROOT = Pathname(__dir__).expand_path
def executable(env_name, command)
override = ENV[env_name]
return File.expand_path(override) if override && File.executable?(override)
ENV.fetch("PATH", "").split(File::PATH_SEPARATOR).each do |directory|
candidate = File.join(directory, command)
return candidate if File.file?(candidate) && File.executable?(candidate)
end
nil
end
def literal(value)
case value
when String then JSON.generate(value)
when TrueClass then "true"
when FalseClass then "false"
when Numeric then value.to_s
when Array then "[#{value.map { |item| literal(item) }.join(",")}]"
else raise "Cannot convert #{value.inspect} to OpenSCAD"
end
end
def run!(*command, env: {})
stdout, stderr, status = Open3.capture3(env, *command)
return if status.success?
warn [stdout, stderr].reject(&:empty?).join("\n")
raise "Command failed (#{status.exitstatus}): #{command.first}"
end
config = YAML.safe_load_file(ROOT.join("case.yml"), permitted_classes: [],
permitted_symbols: [], aliases: false)
openscad = executable("OPENSCAD", "openscad")
blender = executable("BLENDER", "blender")
abort "OpenSCAD not found; install it or set OPENSCAD" unless openscad
abort "Blender not found; install it or set BLENDER" unless blender
parameters = config.fetch("parameters").merge(
"extra_cutouts" => config.fetch("resolved").fetch("extra_cutouts")
)
parts = %w[body lid] + config.fetch("outputs").fetch("coupons")
buttons = %w[button_a button_b button_c button_reset]
if parameters["top_profile"] == "oled128x64" &&
buttons.any? { |name| parameters[name] }
parts << "buttons"
end
stage = Pathname(Dir.mktmpdir(".rebuild-", ROOT.to_s))
begin
exports = stage.join("exports")
previews = stage.join("previews")
scratch = stage.join("meshes")
FileUtils.mkdir_p([exports, previews, scratch])
model = ROOT.join("source/feather_case.scad")
renderer = ROOT.join("source/render_stl_previews.py")
export = lambda do |output, part, overrides = {}|
values = parameters.merge(overrides).merge("part" => part)
command = [openscad, "-o", output.to_s]
values.each { |name, value| command.concat(["-D", "#{name}=#{literal(value)}"]) }
run!(*command, model.to_s)
end
config.fetch("outputs").fetch("formats").each do |format|
directory = exports.join(format)
FileUtils.mkdir_p(directory)
parts.each do |part|
puts "Exporting #{part}.#{format}…"
export.call(directory.join("#{part}.#{format}"), part)
end
end
assembly = scratch.join("assembly.stl")
puts "Preparing assembly preview…"
export.call(assembly, "assembly",
"exploded_view" => config.fetch("outputs").fetch("assembly_exploded_view"),
"show_references" => false)
render_env = {"DISPLAY" => nil, "WAYLAND_DISPLAY" => nil}
run!(blender, "--background", "-noaudio", "--python", renderer.to_s, "--",
assembly.to_s, previews.to_s, "assembly", env: render_env)
parts.each do |part|
puts "Rendering #{part} preview…"
mesh = scratch.join("#{part}.stl")
export.call(mesh, part) unless mesh.file?
run!(blender, "--background", "-noaudio", "--python", renderer.to_s, "--",
mesh.to_s, previews.to_s, part, "iso", env: render_env)
end
backup = ROOT.join(".build-old-#{Process.pid}")
FileUtils.mkdir_p(backup)
%w[exports previews].each do |name|
current = ROOT.join(name)
FileUtils.mv(current, backup.join(name)) if current.exist?
end
begin
FileUtils.mv(exports, ROOT.join("exports"))
FileUtils.mv(previews, ROOT.join("previews"))
FileUtils.rm_rf(backup)
rescue StandardError
FileUtils.rm_rf(ROOT.join("exports"))
FileUtils.rm_rf(ROOT.join("previews"))
%w[exports previews].each do |name|
saved = backup.join(name)
FileUtils.mv(saved, ROOT.join(name)) if saved.exist?
end
raise
end
puts "Rebuilt #{ROOT}"
ensure
FileUtils.rm_rf(stage)
end
cases/pan-tilt-head/case.yml
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---
schema_version: 1
name: Pan/Tilt Head
slug: pan-tilt-head
generator:
sha256: 965260d4d402fd8894f30aa863224e2c9b42dc61a1496f01e2f00b509f9624db
created_with: feather-case-wizard
parameters:
top_profile: oled128x64
wing_count: 3
wing_pitch: 12.25
stack_height_override: 38.0
generic_component_height: 3.0
generic_top_gap: 2.0
gps_antenna_height: 6.0
gps_top_gap: 5.0
oled_component_height: 2.4
oled_display_height: 1.5
oled_face_gap: 0.8
button_a: true
button_b: true
button_c: true
button_reset: false
button_projection: 1.5
button_cap_size:
- 5.0
- 3.2
button_flange_size:
- 6.6
- 3.6
button_flange_thickness: 0.9
button_travel: 0.5
button_contact_extension: 0.7
battery_enabled: false
battery_length: 69.0
battery_diameter: 18.0
battery_radial_clearance: 0.6
battery_end_clearance: 1.0
switch_hole_diameter: 12.0
switch_hole_compensation: 0.3
switch_cap_diameter: 8.0
switch_flange_diameter: 16.2
switch_body_length: 24.0
switch_body_diameter: 12.0
switch_wire_allowance: 3.0
tripod_insert_enabled: true
tripod_insert_length: 6.4
tripod_insert_hole_diameter: 8.8
tripod_thread_clearance_diameter: 6.8
tripod_boss_diameter: 14.0
m25_insert_length: 4.0
m25_insert_hole_diameter: 3.7
m25_screw_clearance: 2.8
m25_boss_diameter: 7.0
insert_entry_chamfer: 0.6
insert_melt_relief: 0.8
wall_thickness: 2.4
floor_thickness: 2.4
lid_thickness: 3.2
corner_radius: 4.0
board_bottom_clearance: 5.4
board_side_clearance: 7.0
board_rear_clearance: 20.0
usb_board_wall_gap: 20.0
lid_lip_depth: 2.4
lid_lip_thickness: 1.2
fit_clearance: 0.35
cutout_min_web: 1.2
hole_compensation: 0.2
lid_screw_head_diameter: 5.2
lid_screw_head_height: 2.5
usb_opening_enabled: true
usb_guide_enabled: true
usb_connector_overhang: 2.0
usb_guide_wall_thickness: 1.2
usb_guide_end_gap: 1.0
usb_opening_width: 12.5
usb_opening_height: 7.0
usb_opening_radius: 1.5
usb_vertical_offset: 0.0
cutouts:
- name: Antenna
face: left
shape: circle
horizontal: 30.4
z: 31.299999999999997
width: 6.5
height: 6.5
radius: 3.25
- name: Servo
face: rear
shape: roundrect
horizontal: 20.83
z: 35.0
width: 10.0
height: 5.0
radius: 1.25
- name: Release
face: rear
shape: circle
horizontal: 20.83
z: 20.0
width: 6.0
height: 6.0
radius: 3.0
- name: Power
face: front
shape: circle
horizontal: 20.83
z: 31.65
width: 8.0
height: 8.0
radius: 4.0
outputs:
formats:
- 3mf
coupons: []
assembly_exploded_view: 8
resolved:
extra_cutouts:
- - left
- circle
- 30.4
- 31.299999999999997
- 6.5
- 6.5
- 3.25
- - rear
- roundrect
- 20.83
- 35.0
- 10.0
- 5.0
- 1.25
- - rear
- circle
- 20.83
- 20.0
- 6.0
- 6.0
- 3.0
- - front
- circle
- 20.83
- 31.65
- 8.0
- 8.0
- 4.0
cases/pan-tilt-head/parameters.json
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{
"parameterSets": {
"pan-tilt-head": {
"top_profile": "\"oled128x64\"",
"wing_count": "3",
"wing_pitch": "12.25",
"stack_height_override": "38.0",
"generic_component_height": "3.0",
"generic_top_gap": "2.0",
"gps_antenna_height": "6.0",
"gps_top_gap": "5.0",
"oled_component_height": "2.4",
"oled_display_height": "1.5",
"oled_face_gap": "0.8",
"button_a": "true",
"button_b": "true",
"button_c": "true",
"button_reset": "false",
"button_projection": "1.5",
"button_cap_size": "[5.0,3.2]",
"button_flange_size": "[6.6,3.6]",
"button_flange_thickness": "0.9",
"button_travel": "0.5",
"button_contact_extension": "0.7",
"battery_enabled": "false",
"battery_length": "69.0",
"battery_diameter": "18.0",
"battery_radial_clearance": "0.6",
"battery_end_clearance": "1.0",
"switch_hole_diameter": "12.0",
"switch_hole_compensation": "0.3",
"switch_cap_diameter": "8.0",
"switch_flange_diameter": "16.2",
"switch_body_length": "24.0",
"switch_body_diameter": "12.0",
"switch_wire_allowance": "3.0",
"tripod_insert_enabled": "true",
"tripod_insert_length": "6.4",
"tripod_insert_hole_diameter": "8.8",
"tripod_thread_clearance_diameter": "6.8",
"tripod_boss_diameter": "14.0",
"m25_insert_length": "4.0",
"m25_insert_hole_diameter": "3.7",
"m25_screw_clearance": "2.8",
"m25_boss_diameter": "7.0",
"insert_entry_chamfer": "0.6",
"insert_melt_relief": "0.8",
"wall_thickness": "2.4",
"floor_thickness": "2.4",
"lid_thickness": "3.2",
"corner_radius": "4.0",
"board_bottom_clearance": "5.4",
"board_side_clearance": "7.0",
"board_rear_clearance": "20.0",
"usb_board_wall_gap": "20.0",
"lid_lip_depth": "2.4",
"lid_lip_thickness": "1.2",
"fit_clearance": "0.35",
"cutout_min_web": "1.2",
"hole_compensation": "0.2",
"lid_screw_head_diameter": "5.2",
"lid_screw_head_height": "2.5",
"usb_opening_enabled": "true",
"usb_guide_enabled": "true",
"usb_connector_overhang": "2.0",
"usb_guide_wall_thickness": "1.2",
"usb_guide_end_gap": "1.0",
"usb_opening_width": "12.5",
"usb_opening_height": "7.0",
"usb_opening_radius": "1.5",
"usb_vertical_offset": "0.0"
}
},
"fileFormatVersion": "1"
}
cases/pan-tilt-head/source/feather_case.scad
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/*
* Parametric enclosure for the Adafruit ESP32 Feather V2 and FeatherWings.
*
* Coordinate system:
* X: USB-C wall (0) toward the rear of the case
* Y: non-battery side (0) toward the battery/JST side
* Z: outside bottom (0) upward
*
* Board coordinates are derived from Adafruit's Eagle PCB files:
* https://github.com/adafruit/Adafruit-ESP32-Feather-V2-PCB
* https://github.com/adafruit/Adafruit-OLED-FeatherWing-PCB
*/
/* [Output] */
part = "assembly"; // [assembly,body,lid,buttons,insert_coupon,switch_coupon,fit_coupon]
exploded_view = 8; // [0:1:20]
show_references = true;
/* [Stack] */
top_profile = "generic"; // [generic,gps,oled128x64]
wing_count = 1; // [1:1:8]
wing_pitch = 12.25; // [7:0.1:16]
stack_height_override = 0; // [0:0.1:100]
generic_component_height = 3; // [0:0.1:30]
generic_top_gap = 2; // [0.5:0.1:10]
gps_antenna_height = 6;
gps_top_gap = 5;
oled_component_height = 2.4;
oled_display_height = 1.5;
oled_face_gap = 0.8;
/* [OLED controls] */
button_a = true;
button_b = true;
button_c = true;
button_reset = false;
button_projection = 1.5; // [0.5:0.1:3]
button_cap_size = [5, 3.2];
button_flange_size = [6.6, 3.6];
button_flange_thickness = 0.9;
button_travel = 0.5;
button_contact_extension = 0.7;
/* [Battery and switch] */
battery_enabled = false;
battery_length = 69;
battery_diameter = 18;
battery_radial_clearance = 0.6;
battery_end_clearance = 1;
switch_hole_diameter = 12;
switch_hole_compensation = 0.3;
switch_cap_diameter = 8;
switch_flange_diameter = 16.2;
switch_body_length = 24;
switch_body_diameter = 12;
switch_wire_allowance = 3;
/* [Tripod mount] */
tripod_insert_enabled = false;
tripod_insert_length = 6.4;
tripod_insert_hole_diameter = 8.8;
tripod_thread_clearance_diameter = 6.8;
tripod_boss_diameter = 14;
/* [M2.5 inserts] */
m25_insert_length = 4;
m25_insert_hole_diameter = 3.7;
m25_screw_clearance = 2.8;
m25_boss_diameter = 7;
insert_entry_chamfer = 0.6;
insert_melt_relief = 0.8;
/* [Shell and fit] */
wall_thickness = 2.4;
floor_thickness = 2.4;
lid_thickness = 3.2;
corner_radius = 4;
board_bottom_clearance = 5.4;
board_side_clearance = 7;
board_rear_clearance = 4;
usb_board_wall_gap = 2;
lid_lip_depth = 2.4;
lid_lip_thickness = 1.2;
fit_clearance = 0.35;
cutout_min_web = 1.2;
hole_compensation = 0.2;
lid_screw_head_diameter = 5.2;
lid_screw_head_height = 2.5;
/* [USB-C opening] */
usb_opening_enabled = true;
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_radius = 1.5;
usb_vertical_offset = 0;
/* [Custom wall cutouts] */
// Entry format: [face, shape, u, z, width, height, radius]
// face: front, rear, left, right. u is Y on front/rear and X on left/right.
// shape: circle, rect, roundrect, slot. Circle uses width as its diameter.
extra_cutouts = [];
/* [Calibration] */
coupon_steps = [-0.3, -0.15, 0, 0.15, 0.3];
$fn = $preview ? 36 : 72;
eps = 0.02;
// Adafruit Feather mechanical reference, millimetres.
feather_length = 50.8;
feather_width = 22.86;
board_thickness = 1.6;
mount_x = [2.54, 48.26];
mount_y = [2.54, 20.32];
usb_center_y = 11.43;
// Official 128x64 OLED FeatherWing geometry in Feather-board coordinates.
oled_visible_min = [11.42, 3.78];
oled_visible_size = [30, 15.3];
oled_button_a_xy = [4.318, 15.875];
oled_button_b_xy = [4.318, 11.43];
oled_button_c_xy = [4.318, 6.985];
oled_button_reset_xy = [7.366, 20.828];
effective_floor = tripod_insert_enabled
? max(floor_thickness, tripod_insert_length + insert_melt_relief + 1.2)
: floor_thickness;
effective_board_clearance = max(
board_bottom_clearance,
m25_insert_length + insert_melt_relief + 0.6
);
board_origin_x = wall_thickness + usb_board_wall_gap;
board_origin_y = wall_thickness + board_side_clearance;
board_bottom_z = effective_floor + effective_board_clearance;
board_top_z = board_bottom_z + board_thickness;
usb_center_u = board_origin_y + usb_center_y;
usb_center_z = board_top_z + 1.6 + usb_vertical_offset;
usb_inner_width = usb_opening_width + hole_compensation;
usb_inner_height = usb_opening_height + hole_compensation;
usb_guide_length = max(
0,
usb_board_wall_gap - usb_connector_overhang - usb_guide_end_gap
);
usb_guide_active = usb_opening_enabled && usb_guide_enabled
&& usb_guide_length > 0;
usb_reserved_width = usb_inner_width
+ (usb_guide_active ? 2 * usb_guide_wall_thickness : 0);
usb_reserved_height = usb_inner_height
+ (usb_guide_active ? 2 * usb_guide_wall_thickness : 0);
computed_top_pcb_z = board_top_z + wing_count * wing_pitch;
top_pcb_z = stack_height_override > 0
? board_top_z + stack_height_override
: computed_top_pcb_z;
profile_component_height =
top_profile == "gps" ? gps_antenna_height :
top_profile == "oled128x64" ? oled_component_height :
generic_component_height;
profile_top_gap =
top_profile == "gps" ? gps_top_gap :
top_profile == "oled128x64" ? oled_face_gap :
generic_top_gap;
partition_y = board_origin_y + feather_width + 1;
battery_center_y = partition_y + wall_thickness + battery_radial_clearance
+ battery_diameter / 2;
battery_start_x = board_origin_x + battery_end_clearance;
battery_end_x = battery_start_x + battery_length;
switch_center_x = battery_end_x + max(
switch_body_diameter / 2 + 0.8,
switch_flange_diameter / 2 + 0.5
);
case_length_plain = board_origin_x + feather_length
+ board_rear_clearance + wall_thickness;
case_length_battery = switch_center_x + switch_flange_diameter / 2
+ 1.2 + wall_thickness;
case_length = battery_enabled ? max(case_length_plain, case_length_battery)
: case_length_plain;
case_width_plain = board_origin_y + feather_width
+ board_side_clearance + wall_thickness;
case_width_battery = battery_center_y + battery_diameter / 2
+ battery_radial_clearance + wall_thickness;
case_width = battery_enabled ? max(case_width_plain, case_width_battery)
: case_width_plain;
battery_center_z = effective_floor + battery_radial_clearance
+ battery_diameter / 2;
switch_center_z = max(
effective_floor + switch_flange_diameter / 2 + 1,
battery_center_z
);
electronics_ceiling_z = top_pcb_z + profile_component_height + profile_top_gap;
battery_ceiling_z = battery_enabled
? max(
battery_center_z + battery_diameter / 2 + battery_radial_clearance,
switch_center_z + switch_flange_diameter / 2 + 1
)
: 0;
body_height = max(electronics_ceiling_z, battery_ceiling_z);
lid_boss_r = m25_boss_diameter / 2;
lid_boss_wall_overlap = 0.6;
lid_boss_xy = [
[
wall_thickness + lid_boss_r - lid_boss_wall_overlap,
wall_thickness + lid_boss_r - lid_boss_wall_overlap
],
[
case_length - wall_thickness - lid_boss_r + lid_boss_wall_overlap,
wall_thickness + lid_boss_r - lid_boss_wall_overlap
],
[
wall_thickness + lid_boss_r - lid_boss_wall_overlap,
case_width - wall_thickness - lid_boss_r + lid_boss_wall_overlap
],
[
case_length - wall_thickness - lid_boss_r + lid_boss_wall_overlap,
case_width - wall_thickness - lid_boss_r + lid_boss_wall_overlap
]
];
assert(wing_count >= 1, "wing_count must be at least one");
assert(top_profile == "generic" || top_profile == "gps"
|| top_profile == "oled128x64", "Unsupported top_profile");
assert(wall_thickness >= 1.2, "wall_thickness is too small for 0.6 mm FDM");
assert(lid_lip_thickness >= 1.2, "lid lip needs at least two 0.6 mm lines");
assert(m25_boss_diameter > m25_insert_hole_diameter + 2,
"M2.5 boss does not have enough radial material");
assert(!tripod_insert_enabled
|| tripod_boss_diameter > tripod_insert_hole_diameter + 3,
"Tripod insert boss does not have enough radial material");
assert(usb_opening_enabled || !usb_guide_enabled,
"USB guide requires the USB opening");
function clamp(v, lo, hi) = min(max(v, lo), hi);
function cutout_height(entry) = len(entry) > 5 ? entry[5] : entry[4];
function cutouts_separated(first, second, web) =
abs(first[2] - second[2])
>= (first[4] + second[4]) / 2 + web
|| abs(first[3] - second[3])
>= (cutout_height(first) + cutout_height(second)) / 2 + web;
function cutout_clear_of_usb(entry, web) =
abs(entry[2] - usb_center_u)
>= (entry[4] + usb_reserved_width) / 2 + web
|| abs(entry[3] - usb_center_z)
>= (cutout_height(entry) + usb_reserved_height) / 2 + web;
module validate_cutout_spacing() {
if (len(extra_cutouts) > 1)
for (first = [0 : len(extra_cutouts) - 2],
second = [first + 1 : len(extra_cutouts) - 1])
if (extra_cutouts[first][0] == extra_cutouts[second][0])
assert(
cutouts_separated(
extra_cutouts[first],
extra_cutouts[second],
cutout_min_web
),
"Custom cutouts are too close on the same wall"
);
if (usb_opening_enabled)
for (entry = extra_cutouts)
if (entry[0] == "front")
assert(
cutout_clear_of_usb(entry, cutout_min_web),
"Front cutout is too close to the USB opening or guide"
);
}
module rounded_rect_2d(size, radius) {
r = clamp(radius, 0.01, min(size[0], size[1]) / 2 - 0.01);
hull() {
for (x = [r, size[0] - r], y = [r, size[1] - r])
translate([x, y]) circle(r = r);
}
}
module centered_rounded_rect_2d(size, radius) {
translate([-size[0] / 2, -size[1] / 2])
rounded_rect_2d(size, radius);
}
module centered_rounded_prism(size, height, radius) {
linear_extrude(height = height)
centered_rounded_rect_2d(size, radius);
}
module rounded_box(size, radius) {
linear_extrude(height = size[2])
rounded_rect_2d([size[0], size[1]], radius);
}
module insert_pocket(diameter, depth, entry_z, downward = true) {
bore_d = diameter + hole_compensation;
if (downward) {
translate([0, 0, entry_z - depth])
cylinder(h = depth + eps, d = bore_d);
translate([0, 0, entry_z - insert_entry_chamfer])
cylinder(
h = insert_entry_chamfer + eps,
d1 = bore_d,
d2 = bore_d + 2 * insert_entry_chamfer
);
} else {
translate([0, 0, entry_z - eps])
cylinder(h = depth + eps, d = bore_d);
translate([0, 0, entry_z - eps])
cylinder(
h = insert_entry_chamfer + eps,
d1 = bore_d + 2 * insert_entry_chamfer,
d2 = bore_d
);
}
}
module face_rounded_cutout(face, u, z, width, height, radius) {
r = clamp(radius, 0.01, min(width, height) / 2);
depth = wall_thickness + 2 * eps;
if (face == "front" || face == "rear") {
x0 = face == "front" ? -eps : case_length - wall_thickness - eps;
hull()
for (yy = [u - width / 2 + r, u + width / 2 - r],
zz = [z - height / 2 + r, z + height / 2 - r])
translate([x0, yy, zz])
rotate([0, 90, 0]) cylinder(h = depth, r = r);
} else if (face == "left" || face == "right") {
y0 = face == "left" ? -eps : case_width - wall_thickness - eps;
hull()
for (xx = [u - width / 2 + r, u + width / 2 - r],
zz = [z - height / 2 + r, z + height / 2 - r])
translate([xx, y0, zz])
rotate([-90, 0, 0]) cylinder(h = depth, r = r);
}
}
module face_circle_cutout(face, u, z, diameter) {
depth = wall_thickness + 2 * eps;
if (face == "front")
translate([-eps, u, z])
rotate([0, 90, 0]) cylinder(h = depth, d = diameter);
else if (face == "rear")
translate([case_length - wall_thickness - eps, u, z])
rotate([0, 90, 0]) cylinder(h = depth, d = diameter);
else if (face == "left")
translate([u, -eps, z])
rotate([-90, 0, 0]) cylinder(h = depth, d = diameter);
else if (face == "right")
translate([u, case_width - wall_thickness - eps, z])
rotate([-90, 0, 0]) cylinder(h = depth, d = diameter);
}
module x_rounded_prism(x, length, u, z, width, height, radius) {
r = clamp(radius, 0.01, min(width, height) / 2 - 0.01);
hull()
for (yy = [u - width / 2 + r, u + width / 2 - r],
zz = [z - height / 2 + r, z + height / 2 - r])
translate([x, yy, zz])
rotate([0, 90, 0]) cylinder(h = length, r = r);
}
module usb_guide_shell() {
outer_width = usb_inner_width + 2 * usb_guide_wall_thickness;
outer_height = usb_inner_height + 2 * usb_guide_wall_thickness;
difference() {
x_rounded_prism(
wall_thickness - eps,
usb_guide_length + 2 * eps,
usb_center_u,
usb_center_z,
outer_width,
outer_height,
usb_opening_radius + usb_guide_wall_thickness
);
x_rounded_prism(
wall_thickness - 2 * eps,
usb_guide_length + 4 * eps,
usb_center_u,
usb_center_z,
usb_inner_width,
usb_inner_height,
usb_opening_radius
);
}
}
module custom_wall_cutout(entry) {
face = entry[0];
shape = entry[1];
u = entry[2];
z = entry[3];
width = entry[4];
height = len(entry) > 5 ? entry[5] : width;
radius = len(entry) > 6 ? entry[6] : min(width, height) / 2;
assert(face == "front" || face == "rear"
|| face == "left" || face == "right", "Invalid cutout face");
assert(shape == "circle" || shape == "rect"
|| shape == "roundrect" || shape == "slot", "Invalid cutout shape");
assert(z - height / 2 >= effective_floor,
"Cutout intersects the floor");
assert(z + height / 2 <= body_height - lid_lip_depth,
"Cutout intersects the lid locating lip");
assert(
(face == "front" || face == "rear")
? u - width / 2 >= 0 && u + width / 2 <= case_width
: u - width / 2 >= 0 && u + width / 2 <= case_length,
"Cutout extends beyond its wall"
);
if (shape == "circle")
face_circle_cutout(face, u, z, width);
else
face_rounded_cutout(
face, u, z, width, height,
shape == "rect" ? 0.02 :
shape == "slot" ? min(width, height) / 2 : radius
);
}
module board_standoffs() {
for (mx = mount_x, my = mount_y)
translate([
board_origin_x + mx,
board_origin_y + my,
effective_floor - eps
])
cylinder(
h = effective_board_clearance + eps,
d = m25_boss_diameter
);
}
module lid_bosses() {
for (p = lid_boss_xy)
translate([p[0], p[1], effective_floor - eps])
cylinder(
h = body_height - effective_floor + eps,
d = m25_boss_diameter
);
}
module battery_cradle() {
partition_height = min(
body_height - lid_lip_depth - 0.5,
battery_center_z + battery_diameter / 2 + 1.5
);
rib_width = 2.4;
rib_positions = [
battery_start_x + 4,
(battery_start_x + battery_end_x) / 2,
battery_end_x - 4
];
// Board/battery partition, with a lead-routing notch near the JST end.
difference() {
translate([wall_thickness, partition_y, effective_floor - eps])
cube([
battery_end_x - wall_thickness + battery_end_clearance,
wall_thickness,
partition_height - effective_floor + eps
]);
translate([
board_origin_x + 6.5,
partition_y - eps,
effective_floor + 1.5
])
cube([9, wall_thickness + 2 * eps, 6]);
}
// Three low curved ribs cradle the protected cylindrical pack.
for (x = rib_positions)
difference() {
translate([
x - rib_width / 2,
battery_center_y - battery_diameter / 2
- battery_radial_clearance,
effective_floor - eps
])
cube([
rib_width,
battery_diameter + 2 * battery_radial_clearance,
battery_diameter / 2 + battery_radial_clearance + eps
]);
translate([x - rib_width, battery_center_y, battery_center_z])
rotate([0, 90, 0])
cylinder(
h = rib_width * 2,
d = battery_diameter + 2 * battery_radial_clearance
);
}
// End stops remain below the cell center so the lid can remove vertically.
for (x = [
battery_start_x - battery_end_clearance - wall_thickness,
battery_end_x + battery_end_clearance
])
translate([
x,
battery_center_y - battery_diameter / 2 - battery_radial_clearance,
effective_floor - eps
])
cube([
wall_thickness,
battery_diameter + 2 * battery_radial_clearance,
battery_diameter / 2 + 1 + eps
]);
// Rear cross-strip separates the side-mounted switch body from the cell.
translate([
battery_end_x + battery_end_clearance,
partition_y,
effective_floor - eps
])
cube([
case_length - wall_thickness - battery_end_x - battery_end_clearance,
case_width - wall_thickness - partition_y,
min(body_height - effective_floor, switch_center_z
+ switch_body_diameter / 2 + switch_wire_allowance
- effective_floor) + eps
]);
}
module body_positive() {
union() {
difference() {
rounded_box([case_length, case_width, body_height], corner_radius);
translate([wall_thickness, wall_thickness, effective_floor])
rounded_box([
case_length - 2 * wall_thickness,
case_width - 2 * wall_thickness,
body_height - effective_floor + eps
], max(0.6, corner_radius - wall_thickness));
}
board_standoffs();
lid_bosses();
if (battery_enabled)
battery_cradle();
if (tripod_insert_enabled)
translate([case_length / 2, case_width / 2, 0])
cylinder(h = effective_floor, d = tripod_boss_diameter);
if (usb_guide_active)
usb_guide_shell();
}
}
module body_cutouts() {
// Board mounting insert pockets, loaded from above before the Feather.
for (mx = mount_x, my = mount_y)
translate([board_origin_x + mx, board_origin_y + my, 0])
insert_pocket(
m25_insert_hole_diameter,
m25_insert_length + insert_melt_relief,
board_bottom_z
);
// Lid insert pockets, loaded from the top of the body.
for (p = lid_boss_xy)
translate([p[0], p[1], 0])
insert_pocket(
m25_insert_hole_diameter,
m25_insert_length + insert_melt_relief,
body_height
);
// USB-C cable opening. Connector center is from the official ESP32 V2 PCB.
if (usb_opening_enabled)
face_rounded_cutout(
"front",
usb_center_u,
usb_center_z,
usb_inner_width,
usb_inner_height,
usb_opening_radius
);
if (battery_enabled) {
face_circle_cutout(
"right",
switch_center_x,
switch_center_z,
switch_hole_diameter + switch_hole_compensation
);
// Clear the switch body and its prewired terminals through the rear bay.
translate([
switch_center_x,
case_width - wall_thickness + eps,
switch_center_z
])
rotate([90, 0, 0])
cylinder(
h = switch_body_length + switch_wire_allowance
+ wall_thickness + eps,
d = switch_body_diameter + 2 * fit_clearance
);
}
if (tripod_insert_enabled) {
translate([case_length / 2, case_width / 2, 0]) {
translate([0, 0, -eps])
cylinder(
h = effective_floor + 2 * eps,
d = tripod_thread_clearance_diameter + hole_compensation
);
insert_pocket(
tripod_insert_hole_diameter,
tripod_insert_length + insert_melt_relief,
effective_floor
);
}
}
for (entry = extra_cutouts)
custom_wall_cutout(entry);
}
module body() {
difference() {
body_positive();
body_cutouts();
}
}
module lid_plate_positive() {
union() {
rounded_box([case_length, case_width, lid_thickness], corner_radius);
// Inset rim: exported pointing upward so the outer lid face prints flat.
translate([
wall_thickness + fit_clearance,
wall_thickness + fit_clearance,
lid_thickness
])
linear_extrude(height = lid_lip_depth)
difference() {
rounded_rect_2d([
case_length - 2 * (wall_thickness + fit_clearance),
case_width - 2 * (wall_thickness + fit_clearance)
], max(0.6, corner_radius - wall_thickness));
translate([lid_lip_thickness, lid_lip_thickness])
rounded_rect_2d([
case_length - 2 * (
wall_thickness + fit_clearance
+ lid_lip_thickness
),
case_width - 2 * (
wall_thickness + fit_clearance
+ lid_lip_thickness
)
], max(0.5, corner_radius - wall_thickness
- lid_lip_thickness));
}
}
}
module beveled_oled_window() {
inner_size = oled_visible_size;
outer_size = [oled_visible_size[0] + 3, oled_visible_size[1] + 3];
center = [
board_origin_x + oled_visible_min[0] + oled_visible_size[0] / 2,
board_origin_y + oled_visible_min[1] + oled_visible_size[1] / 2
];
hull() {
translate([center[0], center[1], -eps])
linear_extrude(height = eps)
centered_rounded_rect_2d(outer_size, 1.5);
translate([center[0], center[1], lid_thickness - eps])
linear_extrude(height = 2 * eps)
centered_rounded_rect_2d(inner_size, 0.8);
}
}
module oled_button_lid_cutout(xy) {
center = [board_origin_x + xy[0], board_origin_y + xy[1]];
shaft_size = [
button_cap_size[0] + fit_clearance * 2,
button_cap_size[1] + fit_clearance * 2
];
recess_size = [
button_flange_size[0] + fit_clearance * 2,
button_flange_size[1] + fit_clearance * 2
];
recess_depth = button_flange_thickness + button_travel;
translate([center[0], center[1], -eps])
centered_rounded_prism(
shaft_size,
lid_thickness + 2 * eps,
shaft_size[1] / 2
);
translate([center[0], center[1], lid_thickness - recess_depth])
centered_rounded_prism(
recess_size,
recess_depth + lid_lip_depth + eps,
recess_size[1] / 2
);
}
module lid_cutouts() {
// Through holes plus shallow counterbores for flush M2.5 socket heads.
for (p = lid_boss_xy) {
translate([p[0], p[1], -eps])
cylinder(
h = lid_thickness + lid_lip_depth + 2 * eps,
d = m25_screw_clearance + hole_compensation
);
translate([p[0], p[1], -eps])
cylinder(
h = lid_screw_head_height + eps,
d = lid_screw_head_diameter + hole_compensation
);
}
if (top_profile == "oled128x64") {
beveled_oled_window();
if (button_a) oled_button_lid_cutout(oled_button_a_xy);
if (button_b) oled_button_lid_cutout(oled_button_b_xy);
if (button_c) oled_button_lid_cutout(oled_button_c_xy);
if (button_reset) oled_button_lid_cutout(oled_button_reset_xy);
}
}
module lid() {
difference() {
lid_plate_positive();
lid_cutouts();
}
}
module one_oled_button() {
recess_depth = button_flange_thickness + button_travel;
stem_height = lid_thickness - recess_depth + button_projection;
// Print outer cap face down. The flange and contact nub build upward.
centered_rounded_prism(
button_cap_size,
stem_height,
button_cap_size[1] / 2
);
translate([0, 0, stem_height])
centered_rounded_prism(
button_flange_size,
button_flange_thickness,
button_flange_size[1] / 2
);
translate([0, 0, stem_height + button_flange_thickness])
cylinder(h = button_contact_extension, d = 3);
}
module buttons() {
enabled = [
button_a,
button_b,
button_c,
button_reset
];
count_enabled = len([for (v = enabled) if (v) 1]);
if (count_enabled == 0)
echo("No OLED buttons are enabled.");
for (i = [0 : len(enabled) - 1])
if (enabled[i])
translate([i * (button_flange_size[0] + 3), 0, 0])
one_oled_button();
}
module reference_board() {
color([0.05, 0.25, 0.55, 0.75])
translate([board_origin_x, board_origin_y, board_bottom_z])
rounded_box([feather_length, feather_width, board_thickness], 2.54);
color([0.12, 0.45, 0.75, 0.45])
for (i = [1 : wing_count])
translate([
board_origin_x,
board_origin_y,
board_top_z + i * wing_pitch - board_thickness
])
rounded_box(
[feather_length, feather_width, board_thickness], 2.54
);
}
module reference_top_feature() {
if (top_profile == "gps")
color([0.92, 0.78, 0.35, 0.8])
translate([
board_origin_x + 31,
board_origin_y + (feather_width - 15) / 2,
top_pcb_z
])
cube([15, 15, gps_antenna_height]);
else if (top_profile == "oled128x64") {
color([0.12, 0.12, 0.12, 0.9])
translate([
board_origin_x + oled_visible_min[0],
board_origin_y + oled_visible_min[1],
top_pcb_z
])
cube([
oled_visible_size[0],
oled_visible_size[1],
oled_display_height
]);
color([0.6, 0.6, 0.6, 0.9])
for (xy = [
oled_button_a_xy,
oled_button_b_xy,
oled_button_c_xy,
oled_button_reset_xy
])
translate([
board_origin_x + xy[0],
board_origin_y + xy[1],
top_pcb_z
])
cylinder(h = 1.6, d = 2.1);
} else
color([0.3, 0.65, 0.35, 0.6])
translate([
board_origin_x + 10,
board_origin_y + 4,
top_pcb_z
])
cube([
feather_length - 20,
feather_width - 8,
generic_component_height
]);
}
module reference_battery_and_switch() {
if (battery_enabled) {
color([0.35, 0.18, 0.55, 0.75])
translate([battery_start_x, battery_center_y, battery_center_z])
rotate([0, 90, 0])
cylinder(h = battery_length, d = battery_diameter);
color([0.8, 0.15, 0.1, 0.65])
translate([
switch_center_x,
case_width - wall_thickness,
switch_center_z
])
rotate([90, 0, 0]) {
cylinder(h = switch_body_length, d = switch_body_diameter);
translate([0, 0, -1.5])
cylinder(h = 1.5, d = switch_flange_diameter);
translate([0, 0, -3])
cylinder(h = 3, d = switch_cap_diameter);
}
}
}
module assembly() {
color([0.82, 0.84, 0.88, 1]) body();
if ($preview && show_references) {
reference_board();
reference_top_feature();
reference_battery_and_switch();
}
// Printable lid is mirrored into its installed orientation and exploded up.
color([0.92, 0.92, 0.95, 0.88])
translate([0, case_width, body_height + lid_thickness + exploded_view])
rotate([180, 0, 0])
lid();
}
module coupon_hole(x, y, diameter, depth) {
translate([x, y, -eps]) cylinder(h = depth + 2 * eps, d = diameter);
}
module insert_coupon() {
spacing = 15;
coupon_length = spacing * len(coupon_steps) + 8;
coupon_width = 32;
coupon_height = max(
m25_insert_length + insert_melt_relief + 1.2,
tripod_insert_length + insert_melt_relief + 1.2
);
difference() {
rounded_box([coupon_length, coupon_width, coupon_height], 3);
for (i = [0 : len(coupon_steps) - 1]) {
x = 7 + i * spacing;
coupon_hole(
x, 8,
m25_insert_hole_diameter + coupon_steps[i],
m25_insert_length + insert_melt_relief
);
coupon_hole(
x, 23,
tripod_insert_hole_diameter + coupon_steps[i],
tripod_insert_length + insert_melt_relief
);
}
}
}
module switch_coupon() {
spacing = 18;
coupon_length = spacing * len(coupon_steps) + 6;
coupon_width = 24;
coupon_height = wall_thickness;
difference() {
rounded_box([coupon_length, coupon_width, coupon_height], 3);
for (i = [0 : len(coupon_steps) - 1])
translate([6 + i * spacing, coupon_width / 2, -eps])
cylinder(
h = coupon_height + 2 * eps,
d = switch_hole_diameter + coupon_steps[i]
);
}
}
module fit_coupon() {
segment_length = 34;
base_width = 16;
base_height = 6;
cavity_size = [segment_length - 8, base_width - 8];
male_size = [
cavity_size[0] - 2 * fit_clearance,
cavity_size[1] - 2 * fit_clearance
];
difference() {
rounded_box([segment_length, base_width, base_height], 2);
translate([4, 4, 2])
cube([segment_length - 8, base_width - 8, base_height]);
}
translate([segment_length + 5, 0, 0])
union() {
cube([segment_length, base_width, lid_thickness]);
translate([
4 + fit_clearance,
4 + fit_clearance,
lid_thickness - eps
])
linear_extrude(height = lid_lip_depth + eps)
difference() {
rounded_rect_2d(male_size, 1);
translate([lid_lip_thickness, lid_lip_thickness])
rounded_rect_2d([
male_size[0] - 2 * lid_lip_thickness,
male_size[1] - 2 * lid_lip_thickness
], 0.5);
}
}
}
validate_cutout_spacing();
if (part == "assembly")
assembly();
else if (part == "body")
body();
else if (part == "lid")
lid();
else if (part == "buttons")
buttons();
else if (part == "insert_coupon")
insert_coupon();
else if (part == "switch_coupon")
switch_coupon();
else if (part == "fit_coupon")
fit_coupon();
else
assert(false, str("Unknown part: ", part));
cases/pan-tilt-head/source/render_stl_previews.py
+127
View File
@@ -0,0 +1,127 @@
"""Render six inspection views of an STL using Blender.
Usage:
blender --background --python tools/render_stl_previews.py -- \
input.stl output-directory basename [comma-separated-views]
"""
import os
import sys
import bpy
from mathutils import Vector
def arguments():
args = sys.argv[sys.argv.index("--") + 1 :]
if len(args) not in (3, 4):
raise SystemExit(
"expected: input.stl output-directory basename [comma-separated-views]"
)
requested_views = args[3].split(",") if len(args) == 4 else None
return args[0], args[1], args[2], requested_views
def look_at(camera, target):
direction = Vector(target) - camera.location
camera.rotation_euler = direction.to_track_quat("-Z", "Y").to_euler()
def render_view(camera, center, span, name, direction, output_dir, basename):
distance = span * 2.2
camera.location = Vector(center) + Vector(direction).normalized() * distance
look_at(camera, center)
camera.data.type = "ORTHO"
camera.data.ortho_scale = span * 1.35
bpy.context.scene.render.filepath = os.path.join(
output_dir, f"{basename}_{name}.png"
)
bpy.ops.render.render(write_still=True)
def main():
input_path, output_dir, basename, requested_views = arguments()
os.makedirs(output_dir, exist_ok=True)
bpy.ops.wm.read_factory_settings(use_empty=True)
bpy.ops.wm.stl_import(filepath=os.path.abspath(input_path))
model = bpy.context.selected_objects[0]
model.name = "Feather case"
material = bpy.data.materials.new("Case material")
material.diffuse_color = (0.16, 0.42, 0.72, 1.0)
material.metallic = 0.0
material.roughness = 0.45
model.data.materials.append(material)
corners = [model.matrix_world @ Vector(corner) for corner in model.bound_box]
mins = Vector([min(v[i] for v in corners) for i in range(3)])
maxs = Vector([max(v[i] for v in corners) for i in range(3)])
center = (mins + maxs) / 2
span = max(maxs - mins)
world = bpy.data.worlds.new("Inspection world")
world.use_nodes = True
world.node_tree.nodes["Background"].inputs["Color"].default_value = (
0.035,
0.04,
0.05,
1,
)
world.node_tree.nodes["Background"].inputs["Strength"].default_value = 0.5
bpy.context.scene.world = world
camera_data = bpy.data.cameras.new("Camera")
camera = bpy.data.objects.new("Camera", camera_data)
bpy.context.collection.objects.link(camera)
bpy.context.scene.camera = camera
key_data = bpy.data.lights.new("Key", type="AREA")
key_data.energy = 900
key_data.shape = "DISK"
key_data.size = span
key = bpy.data.objects.new("Key", key_data)
key.location = center + Vector((span, -span, span * 1.5))
bpy.context.collection.objects.link(key)
fill_data = bpy.data.lights.new("Fill", type="AREA")
fill_data.energy = 500
fill_data.size = span
fill = bpy.data.objects.new("Fill", fill_data)
fill.location = center + Vector((-span, span, span))
bpy.context.collection.objects.link(fill)
scene = bpy.context.scene
scene.render.engine = "BLENDER_WORKBENCH"
scene.render.resolution_x = 800
scene.render.resolution_y = 600
scene.render.resolution_percentage = 100
scene.render.image_settings.file_format = "PNG"
scene.render.film_transparent = False
scene.display.shading.light = "STUDIO"
scene.display.shading.color_type = "MATERIAL"
scene.display.shading.show_shadows = True
scene.display.shading.show_cavity = True
scene.display.shading.cavity_type = "BOTH"
scene.display.shading.curvature_ridge_factor = 1.5
scene.display.shading.curvature_valley_factor = 1.2
views = {
"iso": (1, -1, 0.8),
"front": (-1, 0, 0),
"back": (1, 0, 0),
"left": (0, -1, 0),
"right": (0, 1, 0),
"top": (0, 0, 1),
}
selected = requested_views or list(views)
unknown = sorted(set(selected) - set(views))
if unknown:
raise SystemExit(f"unknown views: {', '.join(unknown)}")
for name in selected:
direction = views[name]
render_view(camera, center, span, name, direction, output_dir, basename)
if __name__ == "__main__":
main()
feather_case.scad
+107 -13
View File
@@ -19,13 +19,14 @@ show_references = true;
/* [Stack] */
top_profile = "generic"; // [generic,gps,oled128x64]
wing_count = 1; // [1:1:8]
wing_pitch = 11; // [7:0.1:16]
wing_pitch = 12.25; // [7:0.1:16]
stack_height_override = 0; // [0:0.1:100]
generic_component_height = 3; // [0:0.1:30]
generic_top_gap = 2; // [0.5:0.1:10]
gps_antenna_height = 4;
gps_antenna_height = 6;
gps_top_gap = 5;
oled_component_height = 2.4;
oled_display_height = 1.5;
oled_face_gap = 0.8;
/* [OLED controls] */
@@ -77,15 +78,21 @@ corner_radius = 4;
board_bottom_clearance = 5.4;
board_side_clearance = 7;
board_rear_clearance = 4;
usb_board_wall_gap = 1.2;
usb_board_wall_gap = 2;
lid_lip_depth = 2.4;
lid_lip_thickness = 1.2;
fit_clearance = 0.35;
cutout_min_web = 1.2;
hole_compensation = 0.2;
lid_screw_head_diameter = 5.2;
lid_screw_head_height = 2.5;
/* [USB-C opening] */
usb_opening_enabled = true;
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_radius = 1.5;
@@ -131,6 +138,20 @@ board_origin_x = wall_thickness + usb_board_wall_gap;
board_origin_y = wall_thickness + board_side_clearance;
board_bottom_z = effective_floor + effective_board_clearance;
board_top_z = board_bottom_z + board_thickness;
usb_center_u = board_origin_y + usb_center_y;
usb_center_z = board_top_z + 1.6 + usb_vertical_offset;
usb_inner_width = usb_opening_width + hole_compensation;
usb_inner_height = usb_opening_height + hole_compensation;
usb_guide_length = max(
0,
usb_board_wall_gap - usb_connector_overhang - usb_guide_end_gap
);
usb_guide_active = usb_opening_enabled && usb_guide_enabled
&& usb_guide_length > 0;
usb_reserved_width = usb_inner_width
+ (usb_guide_active ? 2 * usb_guide_wall_thickness : 0);
usb_reserved_height = usb_inner_height
+ (usb_guide_active ? 2 * usb_guide_wall_thickness : 0);
computed_top_pcb_z = board_top_z + wing_count * wing_pitch;
top_pcb_z = stack_height_override > 0
@@ -215,8 +236,43 @@ assert(m25_boss_diameter > m25_insert_hole_diameter + 2,
assert(!tripod_insert_enabled
|| tripod_boss_diameter > tripod_insert_hole_diameter + 3,
"Tripod insert boss does not have enough radial material");
assert(usb_opening_enabled || !usb_guide_enabled,
"USB guide requires the USB opening");
function clamp(v, lo, hi) = min(max(v, lo), hi);
function cutout_height(entry) = len(entry) > 5 ? entry[5] : entry[4];
function cutouts_separated(first, second, web) =
abs(first[2] - second[2])
>= (first[4] + second[4]) / 2 + web
|| abs(first[3] - second[3])
>= (cutout_height(first) + cutout_height(second)) / 2 + web;
function cutout_clear_of_usb(entry, web) =
abs(entry[2] - usb_center_u)
>= (entry[4] + usb_reserved_width) / 2 + web
|| abs(entry[3] - usb_center_z)
>= (cutout_height(entry) + usb_reserved_height) / 2 + web;
module validate_cutout_spacing() {
if (len(extra_cutouts) > 1)
for (first = [0 : len(extra_cutouts) - 2],
second = [first + 1 : len(extra_cutouts) - 1])
if (extra_cutouts[first][0] == extra_cutouts[second][0])
assert(
cutouts_separated(
extra_cutouts[first],
extra_cutouts[second],
cutout_min_web
),
"Custom cutouts are too close on the same wall"
);
if (usb_opening_enabled)
for (entry = extra_cutouts)
if (entry[0] == "front")
assert(
cutout_clear_of_usb(entry, cutout_min_web),
"Front cutout is too close to the USB opening or guide"
);
}
module rounded_rect_2d(size, radius) {
r = clamp(radius, 0.01, min(size[0], size[1]) / 2 - 0.01);
@@ -300,6 +356,40 @@ module face_circle_cutout(face, u, z, diameter) {
rotate([-90, 0, 0]) cylinder(h = depth, d = diameter);
}
module x_rounded_prism(x, length, u, z, width, height, radius) {
r = clamp(radius, 0.01, min(width, height) / 2 - 0.01);
hull()
for (yy = [u - width / 2 + r, u + width / 2 - r],
zz = [z - height / 2 + r, z + height / 2 - r])
translate([x, yy, zz])
rotate([0, 90, 0]) cylinder(h = length, r = r);
}
module usb_guide_shell() {
outer_width = usb_inner_width + 2 * usb_guide_wall_thickness;
outer_height = usb_inner_height + 2 * usb_guide_wall_thickness;
difference() {
x_rounded_prism(
wall_thickness - eps,
usb_guide_length + 2 * eps,
usb_center_u,
usb_center_z,
outer_width,
outer_height,
usb_opening_radius + usb_guide_wall_thickness
);
x_rounded_prism(
wall_thickness - 2 * eps,
usb_guide_length + 4 * eps,
usb_center_u,
usb_center_z,
usb_inner_width,
usb_inner_height,
usb_opening_radius
);
}
}
module custom_wall_cutout(entry) {
face = entry[0];
shape = entry[1];
@@ -454,6 +544,8 @@ module body_positive() {
if (tripod_insert_enabled)
translate([case_length / 2, case_width / 2, 0])
cylinder(h = effective_floor, d = tripod_boss_diameter);
if (usb_guide_active)
usb_guide_shell();
}
}
@@ -477,15 +569,15 @@ module body_cutouts() {
);
// USB-C cable opening. Connector center is from the official ESP32 V2 PCB.
usb_center_z = board_top_z + 1.6 + usb_vertical_offset;
face_rounded_cutout(
"front",
board_origin_y + usb_center_y,
usb_center_z,
usb_opening_width + hole_compensation,
usb_opening_height + hole_compensation,
usb_opening_radius
);
if (usb_opening_enabled)
face_rounded_cutout(
"front",
usb_center_u,
usb_center_z,
usb_inner_width,
usb_inner_height,
usb_opening_radius
);
if (battery_enabled) {
face_circle_cutout(
@@ -708,7 +800,7 @@ module reference_top_feature() {
cube([
oled_visible_size[0],
oled_visible_size[1],
oled_component_height
oled_display_height
]);
color([0.6, 0.6, 0.6, 0.9])
for (xy = [
@@ -853,6 +945,8 @@ module fit_coupon() {
}
}
validate_cutout_spacing();
if (part == "assembly")
assembly();
else if (part == "body")
lib/feather_case_wizard.rb
+1 -1
View File
@@ -11,6 +11,7 @@ require "yaml"
require "highline"
require_relative "feather_case_wizard/prompting_ui"
require_relative "feather_case_wizard/config"
require_relative "feather_case_wizard/toolchain"
require_relative "feather_case_wizard/package_builder"
@@ -23,4 +24,3 @@ module FeatherCaseWizard
MODEL_SOURCE = ROOT.join("feather_case.scad").freeze
RENDERER_SOURCE = ROOT.join("tools/render_stl_previews.py").freeze
end
lib/feather_case_wizard/cli.rb
+3 -3
View File
@@ -5,18 +5,18 @@ module FeatherCaseWizard
def initialize(ui: HighLine.new, cases_root: CASES_ROOT,
model_source: MODEL_SOURCE, renderer_source: RENDERER_SOURCE,
toolchain: Toolchain.new)
@ui = ui
@ui = PromptingUI.wrap(ui)
@cases_root = Pathname(cases_root)
@model_source = Pathname(model_source)
@renderer_source = Pathname(renderer_source)
@toolchain = toolchain
@wizard = Wizard.new(ui: ui)
@wizard = Wizard.new(ui: @ui)
end
def run
@ui.say(@ui.color("Feather Case Wizard", :bold))
loop do
action = @ui.choose("\nWhat would you like to do?") do |menu|
action = @ui.choose("What would you like to do?") do |menu|
menu.choice("Create a new case") { :create }
menu.choice("Edit an existing case") { :edit }
menu.choice("Rebuild an existing case") { :rebuild }
lib/feather_case_wizard/config.rb
+84 -9
View File
@@ -14,13 +14,14 @@ module FeatherCaseWizard
DEFAULT_PARAMETERS = {
"top_profile" => "generic",
"wing_count" => 1,
"wing_pitch" => 11.0,
"wing_pitch" => 12.25,
"stack_height_override" => 0.0,
"generic_component_height" => 3.0,
"generic_top_gap" => 2.0,
"gps_antenna_height" => 4.0,
"gps_antenna_height" => 6.0,
"gps_top_gap" => 5.0,
"oled_component_height" => 2.4,
"oled_display_height" => 1.5,
"oled_face_gap" => 0.8,
"button_a" => true,
"button_b" => true,
@@ -62,13 +63,19 @@ module FeatherCaseWizard
"board_bottom_clearance" => 5.4,
"board_side_clearance" => 7.0,
"board_rear_clearance" => 4.0,
"usb_board_wall_gap" => 1.2,
"usb_board_wall_gap" => 2.0,
"lid_lip_depth" => 2.4,
"lid_lip_thickness" => 1.2,
"fit_clearance" => 0.35,
"cutout_min_web" => 1.2,
"hole_compensation" => 0.2,
"lid_screw_head_diameter" => 5.2,
"lid_screw_head_height" => 2.5,
"usb_opening_enabled" => true,
"usb_guide_enabled" => true,
"usb_connector_overhang" => 2.0,
"usb_guide_wall_thickness" => 1.2,
"usb_guide_end_gap" => 1.0,
"usb_opening_width" => 12.5,
"usb_opening_height" => 7.0,
"usb_opening_radius" => 1.5,
@@ -77,11 +84,12 @@ module FeatherCaseWizard
ADVANCED_FIELDS = {
"Stack" => %w[wing_pitch generic_component_height generic_top_gap
gps_antenna_height gps_top_gap oled_component_height oled_face_gap],
gps_antenna_height gps_top_gap oled_component_height
oled_display_height oled_face_gap],
"Shell and fit" => %w[wall_thickness floor_thickness lid_thickness corner_radius
board_bottom_clearance board_side_clearance board_rear_clearance
usb_board_wall_gap lid_lip_depth lid_lip_thickness fit_clearance
hole_compensation lid_screw_head_diameter lid_screw_head_height],
board_bottom_clearance board_side_clearance lid_lip_depth
lid_lip_thickness fit_clearance cutout_min_web hole_compensation
lid_screw_head_diameter lid_screw_head_height],
"M2.5 inserts" => %w[m25_insert_length m25_insert_hole_diameter
m25_screw_clearance m25_boss_diameter
insert_entry_chamfer insert_melt_relief],
@@ -93,7 +101,8 @@ module FeatherCaseWizard
switch_flange_diameter switch_body_length
switch_body_diameter switch_wire_allowance],
"USB-C opening" => %w[usb_opening_width usb_opening_height
usb_opening_radius usb_vertical_offset],
usb_opening_radius usb_vertical_offset usb_connector_overhang
usb_guide_wall_thickness usb_guide_end_gap],
"OLED buttons" => %w[button_projection button_flange_thickness
button_travel button_contact_extension]
}.freeze
@@ -264,6 +273,9 @@ module FeatherCaseWizard
unless (outputs["coupons"] - COUPONS).empty?
raise ConfigError, "Unsupported calibration coupon"
end
if parameters["usb_guide_enabled"] && !parameters["usb_opening_enabled"]
raise ConfigError, "USB guide requires the USB opening"
end
positive = DEFAULT_PARAMETERS.keys - %w[usb_vertical_offset stack_height_override]
positive.each do |key|
@@ -289,7 +301,10 @@ module FeatherCaseWizard
def normalize!
data["schema_version"] = Integer(data.fetch("schema_version", SCHEMA_VERSION))
data["generator"] ||= {}
data["parameters"] = self.class.deep_copy(DEFAULT_PARAMETERS).merge(data["parameters"] || {})
supplied_parameters = data["parameters"] || {}
legacy_usb_guide = !supplied_parameters.key?("usb_guide_enabled")
data["parameters"] = self.class.deep_copy(DEFAULT_PARAMETERS).merge(supplied_parameters)
data["parameters"]["usb_guide_enabled"] = false if legacy_usb_guide
data["cutouts"] ||= []
data["outputs"] ||= {}
data["outputs"]["formats"] ||= ["3mf"]
@@ -302,6 +317,7 @@ module FeatherCaseWizard
def validate_cutouts!
dims = dimensions
names = {}
bounds = []
cutouts.each do |cutout|
name = cutout["name"].to_s.strip
raise ConfigError, "Every cutout needs a name" if name.empty?
@@ -328,9 +344,68 @@ module FeatherCaseWizard
radius = Float(cutout.fetch("radius", [width, height].min / 2))
raise ConfigError, "#{name} dimensions must be positive" unless
width.positive? && height.positive? && radius.positive?
bounds << {
"name" => name, "face" => face,
"left" => horizontal - width / 2, "right" => horizontal + width / 2,
"bottom" => z - height / 2, "top" => z + height / 2
}
rescue ArgumentError, TypeError, KeyError => e
raise ConfigError, "Invalid cutout #{name.inspect}: #{e.message}"
end
validate_cutout_spacing!(bounds, dims)
end
def validate_cutout_spacing!(bounds, dims)
web = parameters["cutout_min_web"]
bounds.combination(2) do |first, second|
next unless first["face"] == second["face"]
next if bounds_separated?(first, second, web)
raise ConfigError,
"#{first["name"]} and #{second["name"]} are too close on the #{first["face"]} wall"
end
return unless parameters["usb_opening_enabled"]
usb = usb_wall_bounds(dims)
bounds.select { |item| item["face"] == "front" }.each do |cutout|
next if bounds_separated?(cutout, usb, web)
raise ConfigError, "#{cutout["name"]} is too close to the USB opening or guide"
end
end
def bounds_separated?(first, second, web)
first["right"] + web <= second["left"] ||
second["right"] + web <= first["left"] ||
first["top"] + web <= second["bottom"] ||
second["top"] + web <= first["bottom"]
end
def usb_wall_bounds(dims)
p = parameters
effective_floor = p["tripod_insert_enabled"] ?
[p["floor_thickness"], p["tripod_insert_length"] + p["insert_melt_relief"] + 1.2].max :
p["floor_thickness"]
effective_board_clearance = [
p["board_bottom_clearance"],
p["m25_insert_length"] + p["insert_melt_relief"] + 0.6
].max
board_top_z = effective_floor + effective_board_clearance + 1.6
global_y = p["wall_thickness"] + p["board_side_clearance"] + 11.43
horizontal = dims["width"] - global_y
z = board_top_z + 1.6 + p["usb_vertical_offset"]
guide_length = [
p["usb_board_wall_gap"] - p["usb_connector_overhang"] - p["usb_guide_end_gap"], 0
].max
guide_active = p["usb_guide_enabled"] && guide_length.positive?
shell = guide_active ? 2 * p["usb_guide_wall_thickness"] : 0
width = p["usb_opening_width"] + p["hole_compensation"] + shell
height = p["usb_opening_height"] + p["hole_compensation"] + shell
{
"name" => "USB opening", "face" => "front",
"left" => horizontal - width / 2, "right" => horizontal + width / 2,
"bottom" => z - height / 2, "top" => z + height / 2
}
end
def stringify_keys(value)
lib/feather_case_wizard/prompting_ui.rb
+46
View File
@@ -0,0 +1,46 @@
# frozen_string_literal: true
module FeatherCaseWizard
class PromptingUI
def self.wrap(ui)
ui.is_a?(self) ? ui : new(ui)
end
def initialize(ui)
@ui = ui
end
def ask(*arguments, &block)
separate_after { @ui.ask(*arguments, &block) }
end
def agree(*arguments, &block)
separate_after { @ui.agree(*arguments, &block) }
end
def choose(prompt, &block)
separate_after do
@ui.choose do |menu|
menu.header = prompt.to_s.sub(/[?:]\s*\z/, "")
block.call(menu)
end
end
end
def say(*arguments, &block)
@ui.say(*arguments, &block)
end
def color(*arguments, &block)
@ui.color(*arguments, &block)
end
private
def separate_after
result = yield
@ui.say("\n")
result
end
end
end
lib/feather_case_wizard/wizard.rb
+50 -14
View File
@@ -5,7 +5,7 @@ module FeatherCaseWizard
attr_reader :ui
def initialize(ui: HighLine.new)
@ui = ui
@ui = PromptingUI.wrap(ui)
end
def create
@@ -15,14 +15,14 @@ module FeatherCaseWizard
end
def edit(config)
ui.say("\nEditing #{config.name} (`#{config.slug}`)")
ui.say("Editing #{config.name} (`#{config.slug}`)")
config.data["name"] = text("Case name", config.name)
configure(config, new_case: false)
end
def confirm_build(config)
dims = config.dimensions
ui.say("\n#{ui.color("Build summary", :bold)}")
ui.say(ui.color("Build summary", :bold))
ui.say(" Case: #{config.name} (#{config.slug})")
ui.say(" Profile: #{config.parameters["top_profile"]}")
ui.say(" Wings: #{config.parameters["wing_count"]}")
@@ -42,6 +42,7 @@ module FeatherCaseWizard
choose_formats(config)
choose_profile(config)
choose_stack(config)
choose_end_clearance(config)
choose_features(config)
manage_cutouts(config)
choose_coupons(config)
@@ -63,7 +64,7 @@ module FeatherCaseWizard
menu.choice("3MF") { ["3mf"] }
menu.choice("STL") { ["stl"] }
menu.choice("Both 3MF and STL") { %w[3mf stl] }
menu.default = label == "both" ? 3 : (label == "stl" ? 2 : 1)
menu.default = (label == "both" ? 3 : (label == "stl" ? 2 : 1)).to_s
end
config.outputs["formats"] = selected
end
@@ -74,7 +75,7 @@ module FeatherCaseWizard
menu.choice("Generic / other") { "generic" }
menu.choice("GPS") { "gps" }
menu.choice("128×64 OLED") { "oled128x64" }
menu.default = {"generic" => 1, "gps" => 2, "oled128x64" => 3}.fetch(current)
menu.default = {"generic" => 1, "gps" => 2, "oled128x64" => 3}.fetch(current).to_s
end
end
@@ -82,11 +83,11 @@ module FeatherCaseWizard
p = config.parameters
p["wing_count"] = integer("Number of FeatherWings", p["wing_count"], 1..8)
measured = p["stack_height_override"].positive?
if ui.agree("Use a measured board-to-top-PCB stack height? (y/n) ") do |question|
if ui.agree("Use a measured Feather-PCB-top to top-Wing-PCB stack height? (y/n) ") do |question|
question.default = measured ? "yes" : "no"
end
p["stack_height_override"] = number(
"Measured height in mm", measured ? p["stack_height_override"] :
"PCB-top to PCB-top height in mm", measured ? p["stack_height_override"] :
p["wing_count"] * p["wing_pitch"], min: 0.1
)
else
@@ -96,22 +97,55 @@ module FeatherCaseWizard
def choose_features(config)
p = config.parameters
p["usb_opening_enabled"] = agreement(
"Include front USB-C programming opening?", p["usb_opening_enabled"]
)
p["usb_guide_enabled"] = if p["usb_opening_enabled"]
agreement("Include inward USB plug guide?",
p["usb_guide_enabled"])
else
false
end
p["battery_enabled"] = agreement("Include 18650 battery compartment and switch?",
p["battery_enabled"])
p["tripod_insert_enabled"] = agreement("Include centered 1/4-20 insert?",
p["tripod_insert_enabled"])
return unless p["top_profile"] == "oled128x64"
ui.say("\nOLED captive buttons")
ui.say("OLED captive buttons")
p["button_a"] = agreement("Enable button A?", p["button_a"])
p["button_b"] = agreement("Enable button B?", p["button_b"])
p["button_c"] = agreement("Enable button C?", p["button_c"])
p["button_reset"] = agreement("Enable reset button?", p["button_reset"])
end
def choose_end_clearance(config)
p = config.parameters
defaults = Config::DEFAULT_PARAMETERS
custom = p["usb_board_wall_gap"] != defaults["usb_board_wall_gap"] ||
p["board_rear_clearance"] != defaults["board_rear_clearance"]
enabled = ui.agree("Use extra clearance beyond the Feather PCB ends? (y/n) ") do |question|
question.default = custom ? "yes" : "no"
end
unless enabled
p["usb_board_wall_gap"] = defaults["usb_board_wall_gap"]
p["board_rear_clearance"] = defaults["board_rear_clearance"]
return
end
p["usb_board_wall_gap"] = number(
"USB/front PCB-edge to inner-wall clearance (mm)",
p["usb_board_wall_gap"], min: 0.1
)
p["board_rear_clearance"] = number(
"Rear PCB-edge to inner-wall clearance (mm)",
p["board_rear_clearance"], min: 0.1
)
end
def manage_cutouts(config)
loop do
ui.say("\nCustom cable cutouts: #{config.cutouts.empty? ? "none" :
ui.say("Custom cable cutouts: #{config.cutouts.empty? ? "none" :
config.cutouts.map { |cutout| cutout["name"] }.join(", ")}")
action = ui.choose("Cable cutouts") do |menu|
menu.choice("Done") { :done }
@@ -141,12 +175,15 @@ module FeatherCaseWizard
dims = config.dimensions
name = text("Cutout name", existing["name"] || "cable")
face = ui.choose("Wall") do |menu|
Config::FACES.each { |item| menu.choice(item) { item } }
menu.default = Config::FACES.index(existing["face"]).to_i + 1 if existing["face"]
menu.choice("Front — USB-C short wall") { "front" }
menu.choice("Rear — opposite short wall") { "rear" }
menu.choice("Left — plain/non-JST long wall") { "left" }
menu.choice("Right — JST/battery long wall") { "right" }
menu.default = (Config::FACES.index(existing["face"]).to_i + 1).to_s if existing["face"]
end
shape = ui.choose("Shape") do |menu|
Config::SHAPES.each { |item| menu.choice(item) { item } }
menu.default = Config::SHAPES.index(existing["shape"]).to_i + 1 if existing["shape"]
menu.default = (Config::SHAPES.index(existing["shape"]).to_i + 1).to_s if existing["shape"]
end
wall_width = %w[front rear].include?(face) ? dims["width"] : dims["length"]
ui.say("Viewing the #{face} wall from outside: width #{format("%.1f", wall_width)} mm; " \
@@ -209,7 +246,7 @@ module FeatherCaseWizard
Config::ADVANCED_FIELDS.each do |section, fields|
next unless ui.agree("Adjust #{section.downcase}? (y/n) ") { |q| q.default = "no" }
ui.say("\n#{section}")
ui.say(section)
fields.each do |field|
config.parameters[field] = number(field.tr("_", " "), config.parameters[field],
min: field == "usb_vertical_offset" ? nil : 0.01)
@@ -286,4 +323,3 @@ module FeatherCaseWizard
def yes_no(value) = value ? "yes" : "no"
end
end
test/cli_test.rb
+16
View File
@@ -0,0 +1,16 @@
# frozen_string_literal: true
require "stringio"
require_relative "test_helper"
class CLITest < Minitest::Test
def test_main_prompt_is_not_an_extra_choice
output = StringIO.new
cli = FeatherCaseWizard::CLI.new(ui: HighLine.new(StringIO.new("4\n"), output))
assert_equal 0, cli.run
assert_includes output.string, "What would you like to do:\n"
assert_includes output.string, "4. Exit\n"
refute_includes output.string, "5. What would you like to do?"
end
end
test/config_test.rb
+94 -1
View File
@@ -9,11 +9,77 @@ class ConfigTest < Minitest::Test
def test_default_case_has_expected_parts_and_dimensions
assert_equal %w[body lid], config.printable_parts
assert_in_delta 60.8, config.dimensions["length"], 0.01
assert_in_delta 61.6, config.dimensions["length"], 0.01
assert_in_delta 41.66, config.dimensions["width"], 0.01
assert_in_delta 12.25, config.parameters["wing_pitch"], 0.001
assert_in_delta 6.0, config.parameters["gps_antenna_height"], 0.001
assert_in_delta 2.4, config.parameters["oled_component_height"], 0.001
assert_in_delta 1.5, config.parameters["oled_display_height"], 0.001
assert_in_delta 2.0, config.parameters["usb_board_wall_gap"], 0.001
assert config.parameters["usb_opening_enabled"]
assert config.parameters["usb_guide_enabled"]
assert_equal ["3mf"], config.outputs["formats"]
end
def test_gps_height_uses_stack_pitch_antenna_height_and_top_gap
subject = config
subject.parameters["top_profile"] = "gps"
parameters = subject.parameters
expected_electronics_height =
parameters["wing_pitch"] + parameters["gps_antenna_height"] +
parameters["gps_top_gap"]
assert_in_delta 23.25, expected_electronics_height, 0.001
assert_in_delta 35.85, subject.dimensions["height"] + parameters["lid_thickness"], 0.001
end
def test_oled_height_uses_tallest_component_not_display_reference
subject = config
subject.parameters["top_profile"] = "oled128x64"
original_height = subject.dimensions["height"]
subject.parameters["oled_display_height"] = 10.0
assert_in_delta original_height, subject.dimensions["height"], 0.001
end
def test_older_config_receives_default_oled_display_height
data = FeatherCaseWizard::Config.deep_copy(config.data)
data["parameters"].delete("oled_display_height")
loaded = FeatherCaseWizard::Config.new(data)
assert_in_delta 1.5, loaded.parameters["oled_display_height"], 0.001
end
def test_older_config_preserves_opening_without_enabling_guide
data = FeatherCaseWizard::Config.deep_copy(config.data)
data["parameters"].delete("usb_opening_enabled")
data["parameters"].delete("usb_guide_enabled")
loaded = FeatherCaseWizard::Config.new(data)
assert loaded.parameters["usb_opening_enabled"]
refute loaded.parameters["usb_guide_enabled"]
end
def test_usb_guide_requires_opening
subject = config
subject.parameters["usb_opening_enabled"] = false
error = assert_raises(FeatherCaseWizard::ConfigError) { subject.validate! }
assert_match(/guide requires/, error.message)
end
def test_end_clearances_expand_case_length
subject = config
subject.parameters["usb_board_wall_gap"] = 20.0
subject.parameters["board_rear_clearance"] = 20.0
assert_in_delta 95.6, subject.dimensions["length"], 0.01
end
def test_oled_buttons_and_selected_coupons_are_printable
subject = config
subject.parameters["top_profile"] = "oled128x64"
@@ -50,6 +116,33 @@ class ConfigTest < Minitest::Test
assert_match(/floor/, error.message)
end
def test_cutouts_on_same_wall_require_minimum_web
subject = config
first = cutout("rear", 18.0).merge("name" => "first")
second = cutout("rear", 24.0).merge("name" => "second")
subject.data["cutouts"] = [first, second]
error = assert_raises(FeatherCaseWizard::ConfigError) { subject.validate! }
assert_match(/too close/, error.message)
end
def test_front_cutout_cannot_overlap_usb_opening
subject = config
subject.data["cutouts"] = [
cutout("front", subject.dimensions["width"] / 2).merge("z" => 11.0)
]
error = assert_raises(FeatherCaseWizard::ConfigError) { subject.validate! }
assert_match(/USB opening or guide/, error.message)
end
def test_front_cutout_can_clear_usb_reservation
subject = config
subject.data["cutouts"] = [cutout("front", 10.0).merge("z" => 11.0)]
assert_same subject, subject.validate!
end
def test_yaml_round_trip_preserves_resolved_cutouts
subject = config
subject.data["cutouts"] = [cutout("left", 20.0)]
test/prompting_ui_test.rb
+31
View File
@@ -0,0 +1,31 @@
# frozen_string_literal: true
require "stringio"
require_relative "test_helper"
class PromptingUITest < Minitest::Test
def test_menu_prompt_is_a_header_and_answers_are_separated
output = StringIO.new
ui = FeatherCaseWizard::PromptingUI.wrap(
HighLine.new(StringIO.new("1\nDemo\n"), output)
)
selected = ui.choose("Export format (current: 3mf)") do |menu|
menu.choice("3MF") { "3mf" }
menu.choice("STL") { "stl" }
end
name = ui.ask("Case name: ")
assert_equal "3mf", selected
assert_equal "Demo", name
assert_includes output.string, "Export format (current: 3mf):\n1. 3MF\n2. STL\n? \n"
refute_includes output.string, "3. Export format"
assert_match(/\? \nCase name: /, output.string)
end
def test_wrap_is_idempotent
ui = FeatherCaseWizard::PromptingUI.wrap(HighLine.new)
assert_same ui, FeatherCaseWizard::PromptingUI.wrap(ui)
end
end
test/wizard_test.rb
+53 -14
View File
@@ -6,20 +6,8 @@ require_relative "test_helper"
class WizardTest < Minitest::Test
def test_minimal_new_case_flow_and_confirmation
input = StringIO.new(
"Demo Case\n" \
"\n" \
"1\n" \
"1\n" \
"\n" \
"n\n" \
"n\n" \
"n\n" \
"1\n" \
"n\n" \
"n\n" \
"n\n" \
"n\n" \
"y\n"
["Demo Case", "", "1", "1", "", "n", "n", "", "", "n", "n", "1",
"n", "n", "n", "n", "y"].join("\n") + "\n"
)
output = StringIO.new
wizard = FeatherCaseWizard::Wizard.new(ui: HighLine.new(input, output))
@@ -31,4 +19,55 @@ class WizardTest < Minitest::Test
assert_equal ["3mf"], config.outputs["formats"]
assert_equal %w[body lid], config.printable_parts
end
def test_edit_accepts_current_menu_choices_as_defaults
config = FeatherCaseWizard::Config.create(name: "GPS", slug: "gps")
config.parameters["top_profile"] = "gps"
input = StringIO.new(
["", "", "", "", "n", "n", "", "", "n", "n", "1", "n", "n", "n",
"n"].join("\n") + "\n"
)
wizard = FeatherCaseWizard::Wizard.new(ui: HighLine.new(input, StringIO.new))
edited = wizard.edit(config)
assert_equal ["3mf"], edited.outputs["formats"]
assert_equal "gps", edited.parameters["top_profile"]
end
def test_edit_cutout_accepts_current_wall_and_shape_as_defaults
config = FeatherCaseWizard::Config.create(name: "GPS", slug: "gps")
cutout = {
"name" => "cable",
"face" => "left",
"shape" => "roundrect",
"horizontal" => 30.0,
"z" => 12.0,
"width" => 8.0,
"height" => 6.0,
"radius" => 1.5
}
output = StringIO.new
wizard = FeatherCaseWizard::Wizard.new(ui: HighLine.new(StringIO.new("\n" * 8), output))
edited = wizard.send(:ask_cutout, config, cutout)
assert_equal "left", edited["face"]
assert_equal "roundrect", edited["shape"]
assert_includes output.string, "Wall:\n1. Front — USB-C short wall\n"
assert_includes output.string, "3. Left — plain/non-JST long wall\n"
refute_includes output.string, "5. Wall"
end
def test_end_clearance_step_sets_both_board_end_distances
config = FeatherCaseWizard::Config.create(name: "Servo", slug: "servo")
wizard = FeatherCaseWizard::Wizard.new(
ui: HighLine.new(StringIO.new("y\n20\n20\n"), StringIO.new)
)
wizard.send(:choose_end_clearance, config)
assert_in_delta 20.0, config.parameters["usb_board_wall_gap"], 0.001
assert_in_delta 20.0, config.parameters["board_rear_clearance"], 0.001
end
end