mech: Move generic PCB case to own subdirectory

This should be more decoupled because it is not specific to soundbox. It
might be later extracted to a library repository.

3 files changed, 112 insertions, 0 deletions

diff --git a/mech/pcb_case/common.scad b/mech/pcb_case/common.scad
new file mode 100644
index 0000000..0f79e16
--- /dev/null
+++ b/mech/pcb_case/common.scad
@@ -0,0 +1,17 @@
+nut_h = 3;
+nut_d = 4.15;
+nut_r = nut_d / 2;
+bolt_d = 3;
+bolt_r = bolt_d / 2;
+
+module rounded_cube(dim, radius) {
+	range_y = [radius, dim[1]-radius];
+	range_z = [radius, dim[2]-radius];
+	height = dim[0];
+
+	hull() {
+		for (y=range_y, z=range_z) {
+			translate([0,y,z]) rotate([0,90,0]) cylinder(r=radius, h=height);
+		}
+	}
+}
diff --git a/mech/pcb_case/panel.scad b/mech/pcb_case/panel.scad
new file mode 100644
index 0000000..a42f3a8
--- /dev/null
+++ b/mech/pcb_case/panel.scad
@@ -0,0 +1,15 @@
+use <common.scad>
+
+module pcb_case_panel(dim, t) {
+	rounded_cube([t,dim[1]-2*t,dim[2]-2*t], t);
+}
+
+module pcb_case_panel_back(dim, t) {
+	translate([t,t,t])
+		pcb_case_panel(dim, t);
+}
+
+module pcb_case_panel_front(dim, t) {
+	translate([dim[0]-2*t,t,t])
+		pcb_case_panel(dim, t);
+}
diff --git a/mech/pcb_case/shell.scad b/mech/pcb_case/shell.scad
new file mode 100644
index 0000000..d7bcecc
--- /dev/null
+++ b/mech/pcb_case/shell.scad
@@ -0,0 +1,80 @@
+use <common.scad>
+
+module shell_base(dim, t) {
+	radius = t;
+	difference() {
+		rounded_cube(dim, radius);
+		translate([0,0,dim[2]/2])
+			cube([dim[0], dim[1], dim[2]/2]);
+		translate([3*t, t, t])
+			rounded_cube([dim[0]-6*t, dim[1]-2*t, dim[2]-2*t], radius);
+		translate([0, 2*t, 2*t])
+			rounded_cube([dim[0], dim[1]-4*t, dim[2]-4*t], radius);
+		for (x_off = [t, dim[0]-2*t]) {
+			translate([x_off, t, t])
+				rounded_cube([t, dim[1]-2*t, dim[2]-2*t], radius);
+		}
+		for (x = [dim[0]/4, dim[0]-dim[0]/4]) {
+			translate([x,0,dim[2]/2-1.5*bolt_d])
+				rotate([-90,0,0])
+					cylinder(r=bolt_r, h=1.1*t);
+		}
+	}
+}
+
+module shell_connector(dim, t) {
+	size_x = dim[0]-6*t;
+	size_y = 2*nut_h;
+	size_z = dim[2]/2+3*bolt_d;
+
+	difference () {
+		// base body
+		translate([3*t,dim[1]-t-size_y,0])
+			cube([size_x,size_y,size_z]);
+
+		// bolt holes
+		for (x = [dim[0]/4, dim[0]-dim[0]/4]) {
+			translate([x,dim[1]-t,dim[2]/2+1.5*bolt_d])
+				rotate([90,0,0])
+					cylinder(r=bolt_r, h=size_y);
+		}
+
+		// nut holes
+		for (x = [dim[0]/4, dim[0]-dim[0]/4]) {
+			translate([x,dim[1]-t-size_y,dim[2]/2+1.5*bolt_d])
+				rotate([-90,0,0])
+					cylinder(r=nut_r, h=nut_h);
+		}
+	}
+
+	echo(min_shell_bolt_length=t+size_y);
+}
+
+module pcb_case_shell(dim, t, h, sockets) {
+	difference () {
+		union() {
+			shell_base(dim, t);
+			shell_connector(dim, t);
+			for (socket = [0:len(sockets)-1]) {
+				translate([sockets[socket][0], sockets[socket][1], 0])
+					cylinder(d=nut_d+2, h=h);
+			}
+		}
+		for (socket = [0:len(sockets)-1]) {
+			translate([sockets[socket][0], sockets[socket][1], 0]) {
+				cylinder(d=bolt_d, h=h);
+				cylinder(d=0.9*nut_d, h=nut_h);
+			}
+		}
+	}
+}
+
+module pcb_case_shell_bottom(dim, t, h, sockets) {
+	pcb_case_shell(dim, t, h, sockets);
+}
+
+module pcb_case_shell_top(dim, t) {
+	translate([0,dim[1],dim[2]])
+		rotate([180,0,0])
+			pcb_case_shell(dim, t, 0, []);
+}