add support "feet" to the switch insert

cut out an area for the pcb to sit
b-kelly · Mar 24, 2021 · ad555e9 · ad555e9
1 parent a13320d
commit ad555e9
Showing 1 changed file with 49 additions and 13 deletions.
diff --git a/enclosure.scad b/enclosure.scad
@@ -37,9 +37,20 @@ logoPath = "./Stacks-Icons/src/Icon/Logo.svg";
 // whether to fit the logo to the width or to the height
 fitLogoToLength = true;
 
+// how deep to imprint the image into the faceplate
+imgDepth = 0.24;
+
 // additional height to add to the enclosure to account for electronics, etc
 additionalEnclosureHeight = 5;
 
+// pcb dimensions
+pcbHeight = 1.6;
+pcbWidth = 19.0;
+pcbLength = 34.0;
+
+// how much to add/subtract from friction fit parts to give them some "wiggle room"
+tolerence = 0.1;
+
 // calculate the size of the enclosure based on the keycap widths
 encLength =
     (wallWidth * 2) // two walls
@@ -81,7 +92,7 @@ module post(h)
     // if you do, you run the risk of the post breaking off inside the cap (ask me how I know...)
 
     x = postWidth;
-    y = (postWidth / 4) - 0.2;
+    y = (postWidth / 4) - tolerence;
 
     xh = x / 2;
     yh = y / 2;
@@ -98,19 +109,20 @@ module post(h)
 
 module microUsbCutout(depth = wallWidth)
 {
-    width = 7.40;
-    height = 2.40;
+    width = 7.40 + tolerence;
+    height = 2.40 + tolerence;
 
     translate([width / -2, 0, 0])
         cube([width, depth, height]);
 }
 
+module pcb(height = pcbHeight) {
+    #cube([pcbWidth, pcbLength, height]);
+}
+
 module facePlate(includeImage = true)
 {
     translate([0, wallWidth / 2, 0]) {
-        translate([0, wallWidth / -2, 0])
-            #cube([wallWidth / 2, facePlateLength + wallWidth, encHeight]);
-
         difference() {
             cube([wallWidth, facePlateLength, encHeight]);
 
@@ -119,11 +131,10 @@ module facePlate(includeImage = true)
                 lengthResize = fitLogoToLength ? facePlateLength - wallWidth : 0;
                 heightResize = fitLogoToLength ? 0 : encHeight - wallWidth;
 
-                imgDepth = 0.5;
-                translate([imgDepth, facePlateLength / 2, encHeight / 2])
+                translate([wallWidth - imgDepth, facePlateLength / 2, encHeight / 2])
                     rotate([90, 0, 90])
                     resize([lengthResize, heightResize, 0], auto=[true,true,false])
-                    linear_extrude(imgDepth + 1)
+                    linear_extrude(imgDepth)
                     import(logoPath, center=true);
             }
         }
@@ -140,7 +151,10 @@ difference()
     translate([wallWidth, wallWidth, wallWidth])
         rrect(cornerCurveRadius, encWidth - mod, encLength-mod, encHeight);
 
-    pcbHeight = 1.6;
+    // cutout an area for the pcb to sit, in case it is wider than the curved corners
+    translate([(encWidth - pcbWidth) / 2, wallWidth, wallWidth])
+        pcb();
+
     translate([(encWidth / 2), 0, wallWidth + pcbHeight])
         microUsbCutout();
 
@@ -180,8 +194,30 @@ translate([wallWidth, wallWidth, 0])
 if (includeSwitchInsert)
 translate([encWidth + 5, 0, 0])
 difference() {
-    mod = wallWidth * 2;
-    rrect(cornerCurveRadius, encWidth - mod, encLength - mod, 5);
+    // subtract `tolerence` so it isn't a "flush" fit and will sit inside the enclosure
+    mod = (wallWidth * 2) - tolerence;
+    insertHeight = 5;
+    supportHeight = 9;
+
+    union() {
+        translate([cornerCurveRadius, cornerCurveRadius, 0])
+            cylinder(supportHeight, r=cornerCurveRadius);
+
+        translate([encWidth - cornerCurveRadius - mod, cornerCurveRadius, 0])
+            cylinder(supportHeight, r=cornerCurveRadius);
+
+        translate([cornerCurveRadius, facePlateLength, 0])
+            cylinder(supportHeight, r=cornerCurveRadius);
+
+        translate([encWidth - cornerCurveRadius - mod, encLength - cornerCurveRadius - mod, 0])
+            cylinder(supportHeight, r=cornerCurveRadius);
+
+        rrect(cornerCurveRadius, encWidth - mod, encLength - mod, insertHeight);
+    }
+
+    // make sure to cut out an area for the pcb as well
+    translate([(encWidth - mod - pcbWidth) / 2, 0, insertHeight])
+        pcb(supportHeight);
 
     for (i = [0:(columnCount-1)])
     {
@@ -191,7 +227,7 @@ difference() {
             y = (keycapWidth * i) + (keycapWidth / 2) + distanceFromWalls + (spaceBetweenCaps * i);
 
             translate([x, y, 0])
-                cube([switchWidth, switchWidth, 10], center=true);
+                cube([switchWidth, switchWidth, 100], center=true);
         }
     }
 }