Add most recent version of design and images.

README.md

@@ -6,6 +6,14 @@ Based on ["UniBox" by fjkraan at Printables](https://www.printables.com/model/47
 which was shared under a [Creative Commons (4.0 International License) Attribution](http://creativecommons.org/licenses/by/4.0/)
 license.
 
+Designed in OpenSCAD. It is paramaterized.
+
 Related:
 - [ESP32-based radio controller for radio orienteering/ARDF](https://amiok.net/gitea/W1CDN/vulpes)
 - [Vulpes Radio Orienteering Controller](https://w1cdn.net/projects/vulpes-radio-orienteering-controller/)
+
+![Alt text](docs/vulpes_box_openscad.png "OpenSCAD")
+
+![Photo of 3d-printed box with PCB held in a slot.](docs/vulpes_box_photo_front_open.jpg "PCB in place")
+
+![Photo of same box, with cover on and all openings lined up.](docs/vulpes_box_photo_front.jpg "Cover in place")

vulpes_box.scad

@@ -0,0 +1,221 @@
+//uniBox2
+
+$fn = 32;
+include <./camferCube.scad>
+include <./screwShapes1.scad>
+
+pcbW = 25; // inside width, mm
+pcbL = 90; // inside length, mm
+pcb_margin = 0.5; // extra space on each edge of PCB, but accounted for in pillar and hole location, mm
+bottomHeight = 50; // height of inside wall for side without screws, mm
+screwSideHeight = 3; // mm
+wall = 2; // wall thickness, mm
+pcb_thickness = 2; // leaves gap between pillars for PCB, mm
+pillar_x = 1; // distance in from edge of PCB, mm
+pillar_y = 1; // distance in from edge of PCB, mm
+screw_thread_diam = 1.5; // diameter of pillar that will accept screw threads
+screw_hole_diam = 2.2;
+
+// TODO also consider taking PCB a) dimensions and b) hole spacing and
+// building the box around those values (first screw holes, then box).
+
+// Define box dimensions
+bottomDimsInside = [pcbW + screw_thread_diam + (1.5 * wall),
+                    pcbL + (2 * pcb_margin), 
+                    bottomHeight + wall];
+bottomDimsOutside = bottomDimsInside + [2 * wall, 2 * wall, 0];                    
+screwSideDimsInside = [pcbW + screw_thread_diam + (1.5 * wall), 
+                       pcbL + (2 * pcb_margin), 
+                      screwSideHeight + wall];
+screwSideDimsOutside = screwSideDimsInside + [2 * wall, 2 * wall, 0];                      
+
+// Define pillar XY locations
+pillarSW = [wall + pillar_x , 
+            wall + pillar_y , 
+            wall];
+pillarSE = [bottomDimsInside[0] - pillar_x + wall, 
+            wall + pillar_y, 
+            wall];
+pillarNW = [wall + pillar_x, 
+            bottomDimsInside[1] - pillar_y + wall, 
+            wall];
+pillarNE = [bottomDimsInside[0] - pillar_x + wall, 
+            bottomDimsInside[1] - pillar_y + wall, 
+            wall];  
+// Echo hole spacing
+echo("X screw center spacing: ", pillarSE[0] - pillarSW[0]);   
+echo("Y screw center spacing: ", pillarNE[1] - pillarSE[1]);    
+
+// Define ridge locations
+ridgeWest = [wall/2, bottomDimsInside[1] / 2 + wall, bottomDimsInside[2]];
+ridgeEast = [bottomDimsOutside[0] - wall / 2, bottomDimsInside[1] / 2 + wall , bottomDimsInside[2]];
+ridgeWestScrew = [wall/2, bottomDimsInside[1] / 2 + wall, screwSideDimsInside[2]];
+ridgeEastScrew = [bottomDimsOutside[0] - wall / 2, bottomDimsInside[1] / 2 + wall , screwSideDimsInside[2]];
+                  
+                  
+module bottom(screwSide = false) {
+    difference() {
+        if (screwSide) {
+            difference(){
+                difference() {
+                    camferHalfCube(screwSideDimsOutside, false);
+                    translate([wall, wall, wall]) cube(screwSideDimsInside);
+                }
+                // Add text
+                translate([bottomDimsOutside[0] / 3,
+                           bottomDimsOutside[1] / 3.5, 
+                           1]) rotate([180, 0, 270]) 
+                           linear_extrude(2) 
+                           text("Vulpes v01", valign = "center", halign = "center", size = 6, );
+                translate([bottomDimsOutside[0] / 1.5 ,
+                           bottomDimsOutside[1] / 1.5, 
+                           1]) rotate([180, 0, 270]) 
+                           linear_extrude(2) 
+                           text("W1CDN", valign = "center", halign = "center", size = 6, );
+                
+            }
+        } else {
+            difference() {
+                difference(){
+                    camferHalfCube(bottomDimsOutside, false);
+                    translate([wall, wall, wall]) cube(bottomDimsInside);
+                }
+                
+            }
+        }
+        
+        // side ridge concave
+        translate(ridgeWest) sideRidge();
+        translate(ridgeEast) sideRidge();
+        
+        // Screw insets
+        if (screwSide) {
+             translate(pillarSW) translate([0, 0, -wall - 0.02]) flatHeadM2(bottomHeight);
+             translate(pillarSE) translate([0, 0, -wall - 0.02]) flatHeadM2(bottomHeight);
+             translate(pillarNW) translate([0, 0, -wall - 0.02]) flatHeadM2(bottomHeight);
+             translate(pillarNE) translate([0, 0, -wall - 0.02]) flatHeadM2(bottomHeight);
+             
+             // Holes for Vulpes board v01. 
+             // Lay out holes on XY plane, then rotate into place and move to correct side.
+             // Measure relative to bottom of PCB.
+             translate([bottomDimsInside[0] - (wall * 1.5) - screw_thread_diam,
+                    wall*1.5,
+                    0 + wall/2]){
+                     rotate([0, -180, 90]){
+                        // Key jack
+                        translate([-26, 3, 0]) 
+                            cylinder(d = 8, h = wall + 0.04, center = true);
+                         // Key block
+                        translate([-14, 4, 0]) 
+                            cube([10, 6, wall + 0.04], center = true);
+                        // USB
+                        translate([-59, 14, 0]) 
+                            cube([12, 8, wall + 0.04], center = true);
+                        }
+                    }   
+        } 
+    }
+
+    
+    if (screwSide) { // if screw side
+        // side ridge convex
+        translate(ridgeWestScrew) sideRidge(wall);
+        translate(ridgeEastScrew) sideRidge(wall);
+        // Pillars
+        translate(pillarSW) screwPillar(screwSide, screwSideDimsInside[2] - wall, screw_hole_diam, screw_thread_diam);
+        translate(pillarSE) screwPillar(screwSide, screwSideDimsInside[2] - wall, screw_hole_diam, screw_thread_diam);
+        translate(pillarNW) screwPillar(screwSide, screwSideDimsInside[2] - wall, screw_hole_diam, screw_thread_diam);
+        translate(pillarNE) screwPillar(screwSide, screwSideDimsInside[2] - wall, screw_hole_diam, screw_thread_diam);
+        
+        // Grooves for PCB
+        translate([pillarSE[0] - pcb_thickness - (wall * 1.5) - (screw_thread_diam / 2), wall, 0]) 
+            cube([wall/2, wall*1.5, screwSideDimsInside[2]]);
+        translate([pillarNE[0] - pcb_thickness - (wall * 1.5) - (screw_thread_diam / 2), bottomDimsInside[1] - wall/2, 0]) 
+            cube([wall/2, wall*1.5, screwSideDimsInside[2]]);
+    }
+    else { // if not screw side
+        translate(pillarSW) screwPillar(screwSide, bottomDimsInside[2] - wall, screw_hole_diam, screw_thread_diam);
+        translate(pillarSE) screwPillar(screwSide, bottomDimsInside[2] - wall, screw_hole_diam, screw_thread_diam);
+        translate(pillarNW) screwPillar(screwSide, bottomDimsInside[2] - wall, screw_hole_diam, screw_thread_diam);
+        translate(pillarNE) screwPillar(screwSide, bottomDimsInside[2] - wall, screw_hole_diam, screw_thread_diam);
+        
+        // Grooves for PCB
+        translate([pillarSE[0] - pcb_thickness - (wall * 1.5) - (screw_thread_diam / 2), wall, 0]) 
+            cube([wall/2, wall*1.5, bottomDimsInside[2]]);
+        translate([pillarNE[0] - pcb_thickness - (wall * 1.5) - (screw_thread_diam / 2), bottomDimsInside[1] - wall/2, 0]) 
+            cube([wall/2, wall*1.5, bottomDimsInside[2]]);
+    }
+    
+}
+
+module sideRidge(redux = 0) {
+    ridgeSize = wall * 0.5;
+    rotate([0, 45, 0]) cube([ridgeSize, pcbL - 7 * wall - redux, ridgeSize], true);
+}
+
+module sideRidge2(redux = 0) {
+    ridgeSize = wall * 0.5;
+    rotate([0, 45, 0]) cube([ridgeSize, pcbW - 7 * wall - redux, ridgeSize], true);
+}
+
+module flatHeadM2(length) {
+    headMax = 3.75;
+    headMin = 2.2;
+    headHeight = 2.01;
+    cylinder(d1 = headMax, d2 = headMin, h = headHeight + 0.01);
+    translate([0, 0, headHeight]) cylinder(d = headMin, h = length - headHeight);
+}
+
+module bezelCube(dims, center = false, camfer = 1.0) {
+    width  = dims[0];
+    height = dims[1];
+    length = dims[2];
+    radius = 0.01;
+    translate([width, height, length]) {
+        rotate([-90, 0, 180]) {
+            hull() {
+                // lower plane
+                translate([0, 0, 0]) sphere(r = radius);
+                translate([ width, 0, 0]) sphere(r = radius);
+                translate([0,  length, 0]) sphere(r = radius); 
+                translate([ width,  length, 0]) sphere(r = radius); 
+                // upper plane
+                translate([- camfer, - camfer, height]) sphere(r = radius);
+                translate([ width + camfer, - camfer, height]) sphere(r = radius);
+                translate([- camfer,  length + camfer, height]) sphere(r = radius); 
+                translate([ width + camfer,  length + camfer, height]) sphere(r = radius); 
+            }
+        }
+    }
+}
+
+module screwPillar(screwSide = false, height, insideDiamHole, insideDiamThread) {
+    //insideDiam = 2.6;
+    outsideDiam = insideDiamHole + 1.5 * wall;
+    difference() {
+        union(){
+            cylinder(d = outsideDiam, h = height) ;
+            //cylinder(h = height * 0.15, r2 = (outsideDiam/2), r1 = outsideDiam*0.7);
+            }
+        translate([0, 0, -0.01]) {
+            if (screwSide) {
+                cylinder(d = insideDiamHole, h = height + 0.02);
+            } else {
+                cylinder(d = insideDiamThread, h = height + 0.02);
+            }
+        }
+    }
+    // Extra support at base
+    
+}
+
+// Make the not-screw side
+translate([10 - wall, 0 - wall, 0]) bottom();
+// Make the screw side and scale it
+translate([-pcbW - 10 - wall, 0 - wall, 0])  bottom(true); 
+
+
+
+
+
+