include <../utils/core/core.scad>

use <../vitamins/sheet.scad>

use <../vitamins/screw.scad>

use <../vitamins/washer.scad>

use <../vitamins/insert.scad>

use <../utils/quadrant.scad>

bezel_clearance = 0.2;

sheet_end_clearance = 1;

sheet_slot_clearance = 0.2;

function box_screw(type) = type[0]; //! Screw type to be used at the corners

function box_wall(type) = type[1]; //! Wall thickness of 3D parts

function box_sheets(type) = type[2]; //! Sheet type used for the sides

function box_top_sheet(type) = type[3]; //! Sheet type for the top

function box_base_sheet(type)= type[4]; //! Sheet type for the bottom

function box_feet(type) = type[5]; //! True to enable feet on the bottom bezel

function box_width(type) = type[6]; //! Internal width

function box_depth(type) = type[7]; //! Internal depth

function box_height(type) = type[8]; //! Internal height

function box_bezel_clearance(type) = bezel_clearance;

function box_corner_gap(type) = 3; //! Gap between box_sheets at the corners to connect inside and outside profiles

function box_profile_overlap(type) = 3 + sheet_end_clearance / 2;

function box_washer(type) = screw_washer(box_screw(type));

function box_insert(type) = screw_insert(box_screw(type));

function box_hole_inset(type) = washer_radius(box_washer(type)) + 1;

function box_insert_r(type) = insert_hole_radius(box_insert(type));

function box_insert_l(type) = insert_length(box_insert(type));

function box_boss_r(type) = ceil(corrected_radius(box_insert_r(type)) + box_wall(type));

function box_sheet_slot(type) = sheet_thickness(box_sheets(type)) + sheet_slot_clearance; // add some clearance

function box_corner_overlap(type) = box_wall(type);

function box_corner_rad(type) = box_sheet_slot(type) - sheet_slot_clearance / 2 + box_corner_gap(type) + box_corner_overlap(type);

function box_sheet_r(type) = box_corner_rad(type) - box_sheet_slot(type) - box_corner_overlap(type);

function box_screw_length(type, top) = screw_longer_than(2 * washer_thickness(box_washer(type))

+ sheet_thickness(top ? box_top_sheet(type) : box_base_sheet(type))

+ box_corner_gap(type) + box_profile_overlap(type) + box_insert_l(type) - 1);

function box_wall_clearance(type) = box_sheet_slot(type) / 2 - sheet_thickness(box_sheets(type)) / 2;

function box_margin(type) = box_profile_overlap(type) + box_corner_gap(type); //! How much the bezel intrudes on the specified height

function box_intrusion(type) = box_hole_inset(type) + box_boss_r(type); //! Corner profile intrusion

function sheet_reduction(type) = 2 * box_corner_gap(type) + sheet_end_clearance;

function box_outset(type) = box_sheet_slot(type) + box_wall(type) - sheet_slot_clearance / 2; //! How much the bezel expands the specified internal size

function box_inset(type) = box_wall(type) + sheet_slot_clearance / 2; //! How much the bezel intrudes on the specified width and length, away from the corners

function box_bezel_height(type, bottom) = //! Bezel height for top or bottom

let(t1 = sheet_thickness(box_base_sheet(type)), t2 = sheet_thickness(box_top_sheet(type)))

box_corner_rad(type) + box_profile_overlap(type) + (bottom ? max(t1, t2) : t2) - sheet_thickness(box_sheets(type));

grill_hole = 5;

grill_gap = 1.9;

module grill(width, height, r = 1000, poly = false, h = 0) { //! A staggered array of 5mm holes to make grills in sheets. Can be constrained to be circular. Set ```poly``` ```true``` for printing, ```false``` for milling.

nx = floor(width / (grill_hole + grill_gap));

xpitch = width / nx;

ny = floor(height / ((grill_hole + grill_gap) * cos(30)));

ypitch = height / ny;

extrude_if(h)

for(y = [0 : ny - 1], x = [0 : nx - 1 - (y % 2)]) {

x = -width / 2 + (x + 0.5 + (y % 2) / 2) * xpitch;

y = -height / 2 + (y + 0.5) * ypitch;

if(sqrt(sqr(x) + sqr(y)) + grill_hole / 2 <= r)

translate([x, y])

if(poly)

poly_circle(r = grill_hole / 2);

else

circle(d = grill_hole);

}

}

module box_corner_profile_2D(type) { //! The 2D shape of the corner profile.

t = box_sheet_slot(type);

difference() {

union() {

quadrant(box_hole_inset(type) + box_boss_r(type), box_boss_r(type)); // inside corner

translate([box_corner_gap(type) + box_profile_overlap(type), box_corner_gap(type) + box_profile_overlap(type)])

rotate(180)

quadrant(box_profile_overlap(type) + box_corner_rad(type), box_corner_rad(type)); // outside corner

}

translate([box_corner_gap(type), -t + sheet_slot_clearance / 2])

square([100, t]);

translate([-t + sheet_slot_clearance / 2, box_corner_gap(type)])

square([t, 100]);

}

}

module box_corner_profile(type) { //! Generates the corner profile STL for 3D printing.

stl("box_corner_profile");

length = box_height(type) - 2 * box_margin(type);

difference() {

linear_extrude(height = length, center = true, convexity = 5)

box_corner_profile_2D(type);

for(z = [-1, 1])

translate([box_hole_inset(type), box_hole_inset(type), z * length / 2])

insert_hole(box_insert(type), 5);

}

}

module box_corner_profile_section(type, section, sections) { //! Generates interlocking sections of the corner profile to allow it to be taller than the printer

overlap = 4;

length = box_height(type) - 2 * box_margin(type);

section_length = round_to_layer((length - overlap) / sections);

last_section = section >= sections - 1;

h = last_section ? length - (sections - 1) * section_length : section_length;

overlap_wall = 2;

difference() {

union() {

linear_extrude(height = h, convexity = 5)

box_corner_profile_2D(type);

if(!last_section) // male end always at the top

translate_z(section_length - 1)

for(i = [0 : 1], offset = i * layer_height)

linear_extrude(height = overlap + 1 - offset)

offset(1 + offset - layer_height)

offset(-overlap_wall - 1)

box_corner_profile_2D(type);

}

if(section > 0)

translate_z(last_section ? h : 0) { // female at bottom unless last section

linear_extrude(height = 2 * (overlap + layer_height), center = true, convexity = 5)

offset(-overlap_wall)

box_corner_profile_2D(type);

linear_extrude(height = 2 * layer_height, center = true, convexity = 5)

offset(-overlap_wall + layer_height)

box_corner_profile_2D(type);

}

if(!section || last_section) // insert holes always at the bottom

translate([box_hole_inset(type), box_hole_inset(type)])

insert_hole(box_insert(type), 5);

}

}

module box_corner_quadrants(type, width, depth)

for(corner = [0:3]) {

x = [-1,1,1,-1][corner];

y = [-1,-1,1,1][corner];

translate([x * width / 2, y * depth / 2, 0])

rotate(corner * 90)

quadrant(box_intrusion(type), box_boss_r(type));

}

module box_bezel(type, bottom) { //! Generates top and bottom bezel STLs

stl(bottom ? "bottom_bezel" : "top_bezel");

feet = bottom && box_feet(type);

t = box_sheet_slot(type);

outset = box_outset(type);

inner_r = box_sheet_r(type);

foot_height = box_corner_gap(type) + sheet_thickness(box_base_sheet(type)) + washer_thickness(box_washer(type)) + screw_head_height(box_screw(type)) + box_profile_overlap(type) + 2;

foot_length = box_corner_rad(type) * 2;

height = box_bezel_height(type, bottom);

foot_extension = foot_height - height;

difference() {

translate_z(-box_profile_overlap(type)) difference() {

rounded_rectangle([box_width(type) + 2 * outset, box_depth(type) + 2 * outset, feet ? foot_height : height], box_corner_rad(type), false);

//

// Remove edges between the feet

//

if(feet)

hull() {

translate_z(height + 0.5)

cube([box_width(type) - 2 * foot_length, box_depth(type) + 2 * outset + 1, 1], center = true);

translate_z(foot_height + 1)

cube([box_width(type) - 2 * (foot_length - foot_extension), box_depth(type) + 2 * outset + 1, 1], center = true);

}

if(feet)

hull() {

translate_z(height + 0.5)

cube([box_width(type) + 2 * outset + 1, box_depth(type) - 2 * foot_length, 1], center = true);

translate_z(foot_height + 1)

cube([box_width(type) + 2 * outset + 1, box_depth(type) - 2 * (foot_length - foot_extension), 1], center = true);

}

}

//

// slots for side panels

//

translate_z(-box_profile_overlap(type))

linear_extrude(height = 2 * box_profile_overlap(type), center = true)

for(i = [-1, 1]) {

translate([i * (box_width(type) / 2 + t / 2 - sheet_slot_clearance / 2), 0])

square([t, box_depth(type) - 2 * box_corner_gap(type)], center = true);

translate([0, i * (box_depth(type) / 2 + t / 2 - sheet_slot_clearance / 2)])

square([box_width(type) - 2 * box_corner_gap(type), t], center = true);

}

//

// recess for top / bottom panel

//

translate_z(box_corner_gap(type))

rounded_rectangle([box_width(type) + bezel_clearance, box_depth(type) + bezel_clearance, height], inner_r + bezel_clearance / 2, false);

//

// leave plastic over the corner profiles

//

translate_z(-box_profile_overlap(type) - 1)

linear_extrude(height = box_profile_overlap(type) + box_corner_gap(type) + 2)

union() {

difference() {

square([box_width(type) - 2 * box_inset(type),

box_depth(type) - 2 * box_inset(type)], center = true);

box_corner_quadrants(type, box_width(type), box_depth(type));

}

box_screw_hole_positions(type)

poly_circle(screw_clearance_radius(box_screw(type)));

}

}

}

dowel_length = 20;

dowel_wall = extrusion_width * 3;

dowel_h_wall = layer_height * 6;

module box_bezel_section(type, bottom, rows, cols, x, y) { //! Generates interlocking sections of the bezel to allow it to be bigger than the printer

w = (box_width(type) + 2 * box_outset(type)) / cols;

h = (box_depth(type) + 2 * box_outset(type)) / rows;

bw = box_outset(type) - bezel_clearance / 2;

bw2 = box_outset(type) + box_inset(type);

dw = bw - 2 * dowel_wall;

dh = box_bezel_height(type, bottom) - dowel_h_wall;

dh2 = box_profile_overlap(type) + box_corner_gap(type) - dowel_h_wall;

end_clearance = 0.5;

module male() {

rotate([90, 0, 90])

linear_extrude(height = dowel_length - 2 * end_clearance, center = true)

difference() {

union() {

h = dh - layer_height;

h2 = dh2 - layer_height;

hull() {

translate([bw / 2, h / 2])

square([dw - 1, h], center = true);

translate([bw / 2, (h - 1) / 2])

square([dw, h - 1], center = true);

}

hull() {

translate([bw2 / 2, h2 / 2])

square([bw2 - 2 * dowel_wall - 1, h2], center = true);

translate([bw2 / 2, (h2 - 1) / 2])

square([bw2 - 2 * dowel_wall, h2 - 1], center = true);

}

}

translate([bw2 / 2, 0])

square([box_sheet_slot(type), 2 * box_profile_overlap(type)], center = true);

}

}

module female() {

union() {

translate([0, bw / 2, dh / 2])

cube([dowel_length, dw, dh], center = true);

translate([0, bw2 / 2])

cube([dowel_length, bw2 - 2 * dowel_wall, dh2 * 2], center = true);

hull() {

translate([0, bw / 2, dh / 2])

cube([2, dw, dh], center = true);

translate([0, bw / 2, dh / 2])

cube([eps, dw + 2 * extrusion_width, dh], center = true);

}

hull() {

translate([0, bw2 / 2, dh2 / 2])

cube([2, bw2 - 2 * dowel_wall, dh2], center = true);

translate([0, bw2 / 2, dh2 / 2])

cube([eps, bw2 - 2 * dowel_wall + 2 * extrusion_width, dh2], center = true);

}

}

}

module support() {

if(!$preview)

translate([0, bw / 2 + dw / 2])

cube([dowel_length / 2 - 0.25, 2 * extrusion_width + 0.2, dh2]);

}

union() {

render() difference() {

union() {

clip(xmin = 0, xmax = w, ymin = 0, ymax = h)

translate([box_width(type) / 2 + box_outset(type) - x * w, box_depth(type) / 2 + box_outset(type) - y * h, box_profile_overlap(type)])

box_bezel(type, bottom);

if(x < cols - 1 && y == 0)

translate([w, 0])

male();

if(x > 0 && y == rows - 1)

translate([0, h])

rotate(180)

male();

if(y < rows - 1 && x == cols - 1)

translate([w, h])

rotate(90)

male();

if(y > 0 && x == 0)

rotate(-90)

male();

}

if(x < cols - 1 && y == rows - 1)

translate([w, h])

rotate(180)

female();

if(x > 0 && y == 0)

female();

if(y < rows - 1 && x == 0)

translate([0, h])

rotate(-90)

female();

if(y > 0 && x == cols - 1)

translate([w, 0])

rotate(90)

female();

}

if(x < cols - 1 && y == rows - 1)

translate([w, h])

rotate(180)

support();

if(x > 0 && y == 0)

support();

if(y < rows - 1 && x == 0)

translate([0, h])

rotate(-90)

support();

if(y > 0 && x == cols - 1)

translate([w, 0])

rotate(90)

support();

}

}

module box_screw_hole_positions(type)

for(x = [-1, 1], y = [-1, 1])

translate([x * (box_width(type) / 2 - box_hole_inset(type)), y * (box_depth(type) / 2 - box_hole_inset(type))])

children();

module box_base_blank(type) { //! Generates a 2D template for the base sheet

dxf("box_base");

difference() {

sheet_2D(box_base_sheet(type), box_width(type), box_depth(type), box_sheet_r(type));

box_screw_hole_positions(type)

drill(screw_clearance_radius(box_screw(type)), 0);

}

}

module box_top_blank(type) { //! Generates a 2D template for the top sheet

dxf("box_top");

difference() {

sheet_2D(box_top_sheet(type), box_width(type), box_depth(type), box_sheet_r(type));

box_screw_hole_positions(type)

drill(screw_clearance_radius(box_screw(type)), 0);

}

}

function subst_sheet(type, sheet) =

let(s = box_sheets(type))

sheet ? assert(sheet_thickness(sheet) == sheet_thickness(s)) sheet : s;

module box_shelf_blank(type, sheet = false) { //! Generates a 2D template for a shelf sheet

dxf("box_shelf");

difference() {

sheet_2D(subst_sheet(type, sheet), box_width(type) - bezel_clearance, box_depth(type) - bezel_clearance, 1);

offset(bezel_clearance / 2)

box_corner_quadrants(type, box_width(type), box_depth(type));

}

}

module box_left_blank(type, sheet = false) { //! Generates a 2D template for the left sheet, ```sheet``` can be set to override the type

dxf("box_left");

sheet_2D(subst_sheet(type, sheet), box_depth(type) - sheet_reduction(type), box_height(type) - sheet_reduction(type), 1);

}

module box_right_blank(type, sheet = false) { //! Generates a 2D template for the right sheet, ```sheet``` can be set to override the type

dxf("box_right");

sheet_2D(subst_sheet(type, sheet), box_depth(type) - sheet_reduction(type), box_height(type) - sheet_reduction(type), 1);

}

module box_front_blank(type, sheet = false) { //! Generates a 2D template for the front sheet, ```sheet``` can be set to override the type

dxf("box_front");

sheet_2D(subst_sheet(type, sheet), box_width(type) - sheet_reduction(type), box_height(type) - sheet_reduction(type), 1);

}

module box_back_blank(type, sheet = false) { //! Generates a 2D template for the back sheet, ```sheet``` can be set to override the type

dxf("box_back");

sheet_2D(subst_sheet(type, sheet), box_width(type) - sheet_reduction(type), box_height(type) - sheet_reduction(type), 1);

}

module box_base(type) render_2D_sheet(box_base_sheet(type)) box_base_blank(type); //! Default base, can be overridden to customise

module box_top(type) render_2D_sheet(box_top_sheet(type)) box_top_blank(type); //! Default top, can be overridden to customise

module box_back(type) render_2D_sheet(box_sheets(type)) box_back_blank(type); //! Default back, can be overridden to customise

module box_front(type) render_2D_sheet(box_sheets(type)) box_front_blank(type); //! Default front, can be overridden to customise

module box_left(type) render_2D_sheet(box_sheets(type)) box_left_blank(type); //! Default left side, can be overridden to customise

module box_right(type) render_2D_sheet(box_sheets(type)) box_right_blank(type); //! Default right side, can be overridden to customise