[3d] Add threaded insert support in addition to captive nuts

Also maybe fix weird STL generation cause by intersection volumes when splitting halves?

// preview[view:northeast, tilt:topdiagonal]

/* [Options] */
// Pit probe type
Control_Probe = "Thermocouple"; // [Thermocouple,Thermistor,None]
// Raspberry Pi Model
Pi_Model = "3B/2B/1B+"; // [3B/2B/1B+,Connectorless,1A+,Zero,3A+]
// Which case halves
Pieces = "Both"; // [Both,Top,Bottom]
// Include cutouts and mounts for LCD/Buttons
LCD = 1; // [0:None,1:2-line]
// Thickness of side walls (mm) - Set to trace width multiple
wall = 2.0;
/* [Advanced] */
// Thickness of top and bottom faces (mm)
wall_t = 1.45;
// Height of the body edge bead chamfer (mm)
body_chamfer_height = 1.5;
// Corner ear height (mm) - 0 to disable
MouseEarHeight = 0;
// Corner leg height (mm) - 0 to disable
MouseLegHeight = 0; //body_chamfer_height/2;
// Screw hardware
NutHardware = 0; // [0:Captive Nut,1:Injection Threaded Insert]

/* [Hidden] */
// External corner radius on the body (mm)
body_corner_radius = wall*2-1/2;
w_off = 0.5; // offset the heatermeter origin from the left edge
d_off = 1.0; // offset the heatermeter origin from the front edge
w = inch(3.725)+0.7+w_off; // overall interior case width
d = inch(3.75)+1.0+d_off; // overall interior case depth
// 19.1+ headless Zero
// 22.4 headless Pi3 (limited by nuttrapps interfering with PCB to -6.7)
// 32 standard
h_b = [32.5-6.7, 32.5][LCD];  // overall interior case height

probe_centerline = 9.3; // case is split along probe centerline on the probe side
case_split = 12.4;  // and the case split on the other 3 sides

pic_ex = 1.7;
lcd_mount_t = 8.2 - (wall_t - 0.8);
pi_screw_t = 2.3;

body_chamfer_height_t = body_chamfer_height;
body_chamfer_height_b = body_chamfer_height;

e = 0.01;
is_jig = 0; // generate a jig for soldering LEDs

function inch(x) = x*25.4;

echo(str("Case dimensions (mm): ", w+2*wall, "x", d+2*wall, "x", h_b+2*wall_t));
main();

module main()
{
  if (is_jig) {
    intersection() {
      hm43_split();
      translate([wall+6,-d-wall+3,-e]) cube([w-12,d-8,15]);
    }

    difference() {
      cube([w-12,d-8,8 - wall_t]);
      translate([wall,wall,-e]) cube([w-12-2*wall, d-8-2*wall, 8 - wall_t +2*e]);
    }
  } /* is_jig */
  else
    hm43_split();
}

module cube_fillet_chamfer(size,f,c,$fn=32) {
  hull() {
    translate([f,f,c]) linear_extrude(height=size[2]-2*c) minkowski() {
      square([size[0]-2*f, size[1]-2*f]);
      circle(r=f, $fn=$fn);
    }
    translate([f+c,f+c,0]) linear_extrude(height=size[2]) minkowski() {
      square([size[0]-2*(f+c), size[1]-2*(f+c)]);
      circle(r=f, $fn=$fn);
    }
  }
}

module jhole(d, h) {
  translate([0,0,h/2]) cube([2*(wall+pic_ex),d,h], center=true);
}

module phole() {
  dia=4.5;
  // Hole for thermistor probe jack
  rotate([0,90,0]) cylinder(2*wall, d=dia, $fn=16);
  // because 3d print tends to curl up slightly between the probe holes,
  // do not go right to the edge on the final layer (stop 0.25mm short on each side)
  translate([0,-(dia+0.5)/2, -0.3]) cube([2*wall, dia+0.5, 0.6]);
}

module screwhole() {
  translate([0,0,-e]) cylinder(3.5, d=6, $fn=18);
  translate([0,0,3+0.4]) cylinder(h_b-3.5-0.4+wall_t, d=3.4, $fn=18);
  translate([0.0,0,h_b+wall_t-lcd_mount_t/2-e])
    cylinder(lcd_mount_t/2+e, d=(2.9*2)/sin(60), $fn=6);
}

module pic_ex_cube(interior) {
  translate([0,33.75+interior*(pic_ex+1.3),2])
    cube_fillet([pic_ex+e, 59.8-interior*(pic_ex*2+1.3+1.5), 20.8],
      vertical=[0, (1-interior)*pic_ex, (1-interior)*pic_ex, 0],
      top=[0,pic_ex,0,0],
      bottom=[0,pic_ex,0,0]);
}

module screw_pimount() {
  cylinder(wall_t+pi_screw_t, d=6.4, $fn=18);
  // alignment nubbies
  //cylinder(wall_t+pi_screw_t+1.4, d=2.4, $fn=12);
}

module screw_keyhole() {
  d=6.2;
  d2=3.5;
  off=4.15; // ideally would be D but runs into edge of case
  h=3;

  cylinder(wall_t+2*e, d=d, $fn=18);
  translate([-d2/2,0,0]) cube([d2,off,wall_t+2*e]);
  translate([0,off,0]) {
    cylinder(wall_t+2*e, d=d2, $fn=18);
    translate([0,0,wall_t+e]) cylinder(h+e, d=d, $fn=18);
  }
}

module screw_keyhole_p() {
  d=6.2+wall;
  h=2.3;

  difference() {
    cylinder(wall_t+h, d=d, $fn=18);
    translate([0,0,-e]) cylinder(wall_t+h+2*e, d=d-wall, $fn=18);
    translate([-d,0,-e]) cube([d*2, d/2, wall_t+h+2*e]);
  }
}

module btn_rnd() {
  dia = is_jig ? 6.0 : 7.2;
  cylinder(wall_t+2*e, d1=dia, d2=dia+1.5*wall_t, $fn=24);
  translate([-6.5,-6.5,0]) cube([13,13,0.5+e]);
}

module tc_plusminus() {
  T=0.75+e;
  H=2;
  W=6;
  // Minus
  translate([0,2,0])
    cube_fillet([T, W, H], top=[0,0,0,T]);
  translate([0,-(2+W),0]) {
    cube_fillet([T, W, H], top=[0,0,0,T]);
    translate([0,(W-H)/2,(H-W)/2])
      cube_fillet([T, H, W], top=[0,0,0,T]);
  }
}

module led_hole() {
  dia = is_jig ? 3.2 : 3.4;
  cylinder(wall_t+2*e, d1=dia, d2=dia, $fn=16);
}

module nuttrap() {
  ww_w=3;
  ww_d=wall;
  nut_h=3.2;
  nut_ingress = 5.7;
  nut_d = nut_ingress / sin(60);
  nut_ingress_off = nut_ingress/sqrt(3)/2;
  oa_h=wall_t+0.4+nut_h+wall_t+[0,6.7][LCD];
  screw_l=[20,25][LCD];

  // bottom half for M3 socket cap screw (flush)
  difference() {
    translate([-5.5/2-ww_w, -nut_ingress/2-d_off-e, 0])
      cube_fillet([5.5+2*ww_w, nut_ingress+d_off+ww_d, 6], vertical=[3.4,3.4], $fn=20);
    // socket cap
    translate([0,0,-e]) cylinder(3.5, d=6, $fn=18);
    // screw shaft
    translate([0,0,3.5+0.3]) cylinder(oa_h-3, d=3.4, $fn=18);
  }

  // top half M3 nut trap
  if (NutHardware == 0) { // Captive Nut Slots
    translate([0,0,h_b+wall_t-oa_h])
    difference() {
      translate([-(nut_d/2+ww_w), -nut_ingress/2-d_off, 0])
        cube_fillet([nut_d+2*ww_w, nut_ingress+d_off+ww_d, oa_h+e],
          vertical=[ww_d/2,3.4], $fn=20);
      // M3 screw
      translate([0,0,-e]) cylinder(wall_t, d1=4, d2=3.4, $fn=16);
      // nut hole / M3 extra
      translate([0,0,wall_t+0.3]) {
        // nut 2x for an elongated trap
        translate([-0.2,0,0]) cylinder(nut_h*1.5+e, d=nut_d, $fn=6);
        translate([+0.2,0,0]) cylinder(nut_h*1.5+e, d=nut_d, $fn=6);
        cylinder(oa_h-wall_t-0.3, d=4, $fn=16);  // M3 with plenty of clearance
        //translate([-50,-50,-100]) cube([100,100,100+e]); // cutaway top
      }
      // nut ingress (sideways trapezoid with wider side at ingress)
      translate([nut_ingress_off,-nut_ingress/2,wall_t+0.3])
         linear_extrude(nut_h+e) polygon([[0,0],
           [nut_d/2+ww_w-nut_ingress_off+0.4+e, -0.8],
           [nut_d/2+ww_w-nut_ingress_off+0.4+e, nut_ingress+0.8],
           [0,nut_ingress]]);
    }
  } else if (NutHardware == 1) { // Inection molding threaded insert
    translate([0,0,h_b+wall_t-(h_b-screw_l+2)])
    difference() {
      // 5.0mm dia 5mm tall, with 5.6mm alignment area at top 1.2mm tall
      union() {
        cylinder((h_b-screw_l)+2, d=5.0+2*wall, $fn=24);
        cylinder(1.2-e, d=5.6+2*wall, $fn=24);
        translate([(5.0+2*wall)/-2, -nut_ingress/2-d_off, 0])
          cube([5.0+2*wall, nut_ingress/2+d_off, (h_b-screw_l)+2]);
      }
      cylinder(5+1.2, d=5.0, $fn=24);
      translate([0,0,-e]) cylinder(1.2, d=5.6, $fn=24); // alignment helper
    }
  }
}

module locklip_p(l, l_offset=0,
  lip_insert_depth=2.0, // how deep V to insert
  lip_v_off=0.2, // extra height before starting insert
  lip_h_off=0.4, // back connector away from mating area
  lip_w=2.5,  // thickness of attachment beam
  insert_inset=[0,0] // inset the insert inside mating area
  ) {
  translate([l_offset,0,0]) rotate([90,0,0]) rotate([0,90,0])
    difference() {
      linear_extrude(height=l-2*l_offset) polygon(points=[
        [0.1, -lip_w-lip_insert_depth-lip_h_off],  // 0.1 to add depth to keep extrusion manifold
        [0.1, 0],
        [-lip_insert_depth-lip_h_off, 0],
        [-lip_insert_depth-lip_h_off, lip_v_off],
        [-lip_h_off, lip_v_off+lip_insert_depth],
        [-lip_insert_depth-lip_h_off, lip_v_off+2*lip_insert_depth,],
        [-lip_w-lip_insert_depth-lip_h_off, lip_v_off+2*lip_insert_depth],
        [-lip_w-lip_insert_depth-lip_h_off, 0]
      ]);
      translate([-lip_w-lip_insert_depth-lip_h_off-e, 0, 0]) {
        if (insert_inset[0] > 0)
          translate([0,0,-e])
            cube([lip_w+lip_insert_depth+lip_h_off+2*e,
              lip_v_off+2*lip_insert_depth+e, insert_inset[0]+e]);
        if (insert_inset[1] > 0)
          translate([0, 0, l-2*l_offset-insert_inset[1]])
            cube([lip_w+lip_insert_depth+lip_h_off+2*e,
              lip_v_off+2*lip_insert_depth+e, insert_inset[1]+e]);
      }
    }
}

module locklip_n(l, l_offset=0,
  lip_insert_depth=2.2, // how deep V to insert
  lip_tip_clip=0.3, // how much to shave off the top tip
  ) {
  translate([l-l_offset,0,0]) rotate([90,0,0]) rotate([0,-90,0])
    linear_extrude(height=l-2*l_offset) polygon(points=[
      [0.1, -3*lip_insert_depth],  // 0.1 to add depth to keep extrusion manifold
      [0.1, -lip_tip_clip],
      [-lip_insert_depth+lip_tip_clip, -lip_tip_clip],
      [-e, -lip_insert_depth],
      [-lip_insert_depth, -2*lip_insert_depth]
    ]);
}

module lcd_screw() {
  rotate([180]) difference() {
    //cylinder(lcd_mount_t, d=2.5+3.2, $fn=16);
    cylinder(lcd_mount_t+e, d=2.5, $fn=16);
  }
}

module lcd_mount() {
  // Assuming starting at bottom left screw hole
  //lcd_screw();
  //translate([75,0,0]) lcd_screw(); // bottom right hole obscured by PCB
  translate([0,31,0]) lcd_screw();
  translate([75,31,0]) lcd_screw();
}

module lcd_neg() {
  // Assuming starting at bottom left screw hole
  // (Note LCD is not centered vertically on PCB, top is 5.15, bottom is 4.55mm)
  translate([1.0, 1.55, 0])
    cube([73.0, 27.3, lcd_mount_t+wall_t-0.8]); // black bezel inset
  translate([5.5, 7.5, 0])
    cube([64.0, 15.4, lcd_mount_t+wall_t+2*e]); // LCD active area
  //translate([4.23, -2.5, 0])
  //  cube([16*2.54, 5, lcd_mount_t+wall_t-0.8]); // pins cutout
}

module locklip_top_n(split) {
  translate([wall, d+wall, split+wall_t+e])
    rotate([180]) {
      locklip_n(28);
      translate([w-34,0,0]) locklip_n(34);
    }
}

module hm_base() {
  cube_bchamfer([w+2*wall, d+2*wall, h_b+2*wall_t],
    r=body_corner_radius, top=body_chamfer_height_t,
    bottom=body_chamfer_height_b, $fn=36);
  // extra thick by Pi connectors
  if (Pi_Model != "Zero" && Pi_Model != "1A+" && Pi_Model != "3A+")
    translate([-pic_ex,wall+d_off,wall_t])
      pic_ex_cube(0);
  // TC +/-
  if (Control_Probe == "Thermocouple")
    translate([w+wall*2-e,wall+d_off+10,wall_t+19]) tc_plusminus();
}

module hm43() {
difference() {
  hm_base();

  // Main cutout
  translate([wall, wall, wall_t])
    cube_fillet([w, d, h_b],
      bottom=[pi_screw_t,pi_screw_t,pi_screw_t,pi_screw_t],
      top=[pi_screw_t,pi_screw_t,pi_screw_t,pi_screw_t],
      vertical=[body_corner_radius/2,body_corner_radius/2,body_corner_radius/2,body_corner_radius/2],
      $fn=[36,4,4]);
  if (Pi_Model != "Zero" && Pi_Model != "1A+" && Pi_Model != "3A+")
    translate([wall-pic_ex+e,wall+d_off,wall_t]) pic_ex_cube(1);

  // Probe jack side
  translate([w+wall*0.5, wall+d_off, wall_t+probe_centerline]) {
    // Probe jacks
    if (Control_Probe == "Thermocouple")
      // TC jack
      translate([0,inch(0.4)-16.5/2,-1.1]) cube([2*wall, 16.5, 6.5]);
    else if (Control_Probe == "Thermistor")
      translate([0,inch(0.28),0]) phole();
    if (Control_Probe != "None") {
      translate([0,inch(0.95)+inch(0.37)*0,0]) phole();
      translate([0,inch(0.95)+inch(0.37)*1,0]) phole();
      translate([0,inch(0.95)+inch(0.37)*2,0]) phole();
    }
  }
  // Pi connector side
  translate([0,wall+d_off,wall_t]) {
    // Pi connectors
    translate([0,0,5]) {
      if (Pi_Model == "3B/2B/1B+") {
        // ethernet
        translate([0,81.5,-0.8]) jhole(15,13);
        translate([0,81.5,-1.8]) jhole(5,5);
        // USB 0+1
        translate([0,62.75,0]) jhole(13,14.8);
        translate([0,44.75,0]) jhole(13,14.8);
      }
    }
    // HeaterMeter connectors
    translate([0,0,0]) {
      // Blower/Servo output
      translate([0,25,1.7]) jhole(16.4,13);
      // HM power jack
      translate([0,inch(0.2),4.2]) jhole(9.4,11);
    }
  }

  // lcd hole
  if (LCD)
    translate([wall+10.375+w_off, wall+d_off+inch(2), h_b+wall_t-lcd_mount_t-e]) lcd_neg();

  // button holes
  if (LCD) translate([wall+inch(1.925)+w_off, wall+d_off+inch(1.15), h_b+wall_t-e]) {
    translate([-inch(1.1)/2,0,0]) btn_rnd();  // left
    translate([inch(1.1)/2,0,0]) btn_rnd();   // right
    translate([0,inch(0.9)/2,0]) btn_rnd();   // up
    translate([0,-inch(0.9)/2,0]) btn_rnd();  // down
    // LED holes
    translate([inch(1.3), inch(-0.05), 0]) {
      led_hole();  //red
      translate([0, inch(0.35), 0]) led_hole(); //yellow
      translate([0, inch(0.70), 0]) led_hole(); //green
    }
  }
  // close screw holes
  translate([wall+inch(0.825)+0.5,wall+d_off+inch(0.1),0]) {
    screwhole();
    translate([inch(2.0),0,0]) screwhole();
  }
  // keyholes
  //translate([wall+24,wall+d_off+39,-e]) {
  //    translate([0,49,0]) screw_keyhole();
  //    translate([58,49,0]) screw_keyhole();
  //}
}  // END OF DIFFERENCE

  // Pi mounting screws
  translate([wall+24,wall+d_off+39,0]) {
    translate([0,0,0]) screw_pimount();
    translate([58,0,0]) screw_pimount();
    if (Pi_Model == "Zero") {
      translate([0,23,0]) screw_pimount();
      translate([58,23,0]) screw_pimount();
    }
    else {
      translate([0,49,0]) screw_pimount();
      translate([58,49,0]) screw_pimount();
      //translate([0,49,0]) screw_keyhole_p();
      //translate([58,49,0]) screw_keyhole_p();
    }
  }

  if (Pi_Model != "Zero") {
    // Pi right edge stop
    translate([wall+w-9.5, wall+d_off+35, wall_t])
      difference() {
        cube_fillet([9.5,d-d_off-35,4], vertical=[0,0,10/2], $fn=24);
        // Pi B+ microsd gap
        translate([-e,22,-e]) cube_fillet([5.5,14.5,4+2*e], vertical=[2,0,0,2], $fn=20);
      }
  } // if !Zero

  // close nut traps
  if (!is_jig) translate([wall+inch(0.825)+w_off,wall+d_off+inch(0.1),0]) {
      nuttrap();
      translate([inch(2.0),0,0]) nuttrap();
    }

  // Top locklip (negative)
  if (Pi_Model == "3B/2B/1B+")
    locklip_top_n(case_split);
  else
    locklip_top_n(probe_centerline);

  // LCD mount
  if (LCD) difference() {
    union() {
      // Filled block above LCD hole
      translate([wall, wall+d_off+78, h_b+wall_t-lcd_mount_t])
        cube([w,d-d_off-78,lcd_mount_t+e]);
      // LCD grab notch
      translate([wall+10.375+w_off, wall+d_off+inch(2), h_b+wall_t-lcd_mount_t])
        translate([(77.5-20)/2,34.0-wall_t,-(1.8+wall_t)])
          // 1.8=thickness of LCD pcb
          cube_fillet([20,1.8+wall_t+wall,1.8+wall_t+e], top=[0,0,1.8+wall_t+e],
            vertical=[wall/2,wall/2]);
    }
    translate([wall+10.375+w_off, wall+d_off+inch(2), h_b+wall_t-e]) {
      translate([0, 0, -lcd_mount_t]) lcd_neg();
      // vv Keep screw holes where they have been since the beginning
      translate([0, 0.5, 0]) lcd_mount();
    }
  }

  if (Pi_Model == "3B/2B/1B+")
    translate([-pic_ex, wall+d_off, wall_t+2]) {
      // USB pillar reinforcements
      translate([0, (44.75+62.75)/2-2.2/2, 1.5])
        cube_fillet([pic_ex+wall, 2.2, 20.8-1.5], bottom=[0,pic_ex,0,2], top=[0,pic_ex]);
      translate([0, 81.5-15/2-3, 1.5])
        cube_fillet([pic_ex+wall, 2.5, 20.8-1.5], bottom=[0,pic_ex,0,2], top=[0,pic_ex]);
    }
}

module lip_guide(l) {
  guide_offset = 0.2; // how much to recess the edge guides
  guide_h = 1.2; // how tall above the edge to extend
  linear_extrude(height=l) polygon([
    [0,-e], [wall+guide_offset,-e], [0, wall+guide_offset],
    [-guide_h, wall+guide_offset], [-guide_h, guide_offset],
    [0, guide_offset]
  ]);
}

module hm43_bottom_lips(split) {
  translate([wall, wall, split+wall_t]) {
    // bottom locklip (positive)
    translate([0,d,0]) {
      locklip_p(28, insert_inset=[2,0]);
      translate([w-34,0,0]) locklip_p(34-wall, insert_inset=[0,1]);
    }

    // front guide lip
    translate([w/2-9, 0, 0])
      rotate([0,90]) lip_guide(25);
    // left guide lip assortment
    translate([0, d_off+5.25+9.4/2, 0])
      rotate([-90]) rotate(90) mirror([0,1,0]) lip_guide(25.25-5.25-9.4/2-16.7/2);
    *translate([-pic_ex, d_off+52, 0])
      rotate([-90]) rotate(90) mirror([0,1,0]) lip_guide(3.5);
    *translate([-pic_ex, d_off+70, 0])
      rotate([-90]) rotate(90) mirror([0,1,0]) lip_guide(3.5);
  }
  // probe side guide lip
  translate([wall+w, wall+d-45, probe_centerline+wall_t])
    rotate([-90]) rotate(90) lip_guide(40);
}

module mouseears() {
  me_h = MouseEarHeight;
  me_d = 20;
  me_overlap = wall;
  me_outset_bottom = (me_d/2 - body_corner_radius/4 - body_chamfer_height_b - me_overlap) * 0.707;
  me_outset_top = (me_d/2 - body_corner_radius/4 - body_chamfer_height_t - me_overlap) * 0.707;

  // Bottom outside corners
  if (Pieces != "Top") {
    translate([-me_outset_bottom, d+2*wall+me_outset_bottom, 0])
      cylinder(me_h, d=me_d, $fn=24);
    translate([w+2*wall+me_outset_bottom, d+2*wall+me_outset_bottom, 0])
      cylinder(me_h, d=me_d, $fn=24);
  }

  // top outside corners
  if (Pieces != "Bottom") {
    translate([0,-1,me_h]) rotate([180]) {
      translate([w+2*wall+me_outset_top, d+2*wall+me_outset_top, 0])
        cylinder(me_h, d=me_d, $fn=24);
      translate([-me_outset_top, d+2*wall+me_outset_top, 0])
        cylinder(me_h, d=me_d, $fn=24);
    }
  }

  // common corner area
  translate([-me_outset_bottom/0.707, 0, 0])
    cylinder(me_h, d=me_d, $fn=24);
  translate([w+2*wall+me_outset_bottom/0.707, 0, 0])
    cylinder(me_h, d=me_d, $fn=24);
}

module mouseleg(isBottom) {
  MouseLegWidth = 2*0.63;
  if (isBottom)
    translate([body_chamfer_height_b+0.3, -MouseLegWidth/2, 0])
      cube([body_corner_radius+body_chamfer_height_b, MouseLegWidth, MouseLegHeight]);
  else
    translate([body_chamfer_height_t+0.3, -MouseLegWidth/2, h_b+2*wall_t-MouseLegHeight])
      cube([body_corner_radius+body_chamfer_height_t, MouseLegWidth, MouseLegHeight]);
}

module mouselegs(isBottom) {
  translate([body_chamfer_height_t+body_corner_radius/2,
    body_chamfer_height_t+body_corner_radius/2, 0])
    rotate(-135) mouseleg(isBottom);
  translate([w+2*wall-body_chamfer_height_t-body_corner_radius/2,
    body_chamfer_height_t+body_corner_radius/2, 0])
    rotate(-45) mouseleg(isBottom);
  translate([w+2*wall-body_chamfer_height_t-body_corner_radius/2,
    d+2*wall-body_chamfer_height_t-body_corner_radius/2, 0])
    rotate(45) mouseleg(isBottom);
  translate([body_chamfer_height_t+body_corner_radius/2,
    d+2*wall-body_chamfer_height_t-body_corner_radius/2, 0])
    rotate(135) mouseleg(isBottom);
}

module split_volume() {
  if (Pi_Model == "3B/2B/1B+") {
    difference() {
      translate([-pic_ex-1,-1,-1])
        cube([w+pic_ex+2*wall+2, d+2*wall+2, wall_t+case_split+1]);
      translate([w,0,wall_t+probe_centerline])
        cube([3*wall, d+2*wall+2*e, wall_t+probe_centerline+e]);
    }
  }
  else
    translate([-w,-d,-e])
      cube([3*w, 3*d, wall_t+probe_centerline+2*e]);
}

module hm43_split() {
  // bottom
  if (Pieces != "Top") translate([0,4,0]) {
    intersection() {
      hm43();
      split_volume();
    }
    if (Pi_Model == "3B/2B/1B+")
      hm43_bottom_lips(case_split);
    else
      hm43_bottom_lips(probe_centerline);
    if (MouseLegHeight > 0.0) mouselegs(true);
  } // if include bottom

  // top
  if (Pieces != "Bottom") {
    translate([0,-1,h_b+2*wall_t]) rotate([180]) {
      difference() {
        hm43();
        //translate([11,5,h_b+2*wall_t-0.24]) linear_extrude(0.5)
        //  text("HeaterMeter", font = "Liberation Sans:style=Bold Italic");
        split_volume();
      }
      if (MouseLegHeight > 0.0) mouselegs(false);
    }
  }  // if include top
  if (MouseEarHeight > 0.0)
    color("silver") mouseears();
}

/**********************                               **********************/
/********************** END OF CASE / LIBRARY FOLLOWS **********************/
/**********************                               **********************/

module cube_bchamfer(dim, r, top=0, bottom=0, $fn=$fn) {
  // bottom beaded area
  if (bottom != 0) hull(){
    translate([r,r,0]) cylinder(bottom, r1=r-bottom, r2=r, $fn=$fn);
    translate([dim[0]-r,r,0]) cylinder(bottom, r1=r-bottom, r2=r, $fn=$fn);
    translate([r,dim[1]-r,0]) cylinder(bottom, r1=r-bottom, r2=r, $fn=$fn);
    translate([dim[0]-r,dim[1]-r,0]) cylinder(bottom, r1=r-bottom, r2=r, $fn=$fn);
  }
  // center
  translate([0,0,bottom]) hull(){
    translate([r,r,0]) cylinder(dim[2]-top-bottom, r=r, $fn=$fn);
    translate([dim[0]-r,r,0]) cylinder(dim[2]-top-bottom, r=r, $fn=$fn);
    translate([r,dim[1]-r,0]) cylinder(dim[2]-top-bottom, r=r, $fn=$fn);
    translate([dim[0]-r,dim[1]-r,0]) cylinder(dim[2]-top-bottom, r=r, $fn=$fn);
  }
  // top beaded area
  if (top != 0) translate([0,0,dim[2]-top]) hull(){
    translate([r,r,0]) cylinder(top, r2=r-top, r1=r, $fn=$fn);
    translate([dim[0]-r,r,0]) cylinder(top, r2=r-top, r1=r, $fn=$fn);
    translate([r,dim[1]-r,0]) cylinder(top, r2=r-top, r1=r, $fn=$fn);
    translate([dim[0]-r,dim[1]-r,0]) cylinder(top, r2=r-top, r1=r, $fn=$fn);
  }
}

module fillet(radius, height=100, $fn=$fn) {
  if (radius > 0) {
    //this creates acutal fillet
    translate([-radius, -radius, -height / 2 - 0.02]) difference() {
        cube([radius * 2, radius * 2, height + 0.04]);
        if ($fn == 0 && (radius == 2 || radius == 3 || radius == 4)) {
            cylinder(r=radius, h=height + 0.04, $fn=4 * radius);
        } else {
            cylinder(r=radius, h=height + 0.04, $fn=$fn);
        }

    }
  }
}

module cube_fillet(size, radius=-1, vertical=[0,0,0,0], top=[0,0,0,0], bottom=[0,0,0,0], center=false, $fn=4){
    if (center) {
        cube_fillet_inside(size, radius, vertical, top, bottom, $fn);
    } else {
        translate([size[0]/2, size[1]/2, size[2]/2])
            cube_fillet_inside(size, radius, vertical, top, bottom, $fn);
    }
}

module cube_negative_fillet(size, radius=-1, vertical=[3,3,3,3], top=[0,0,0,0], bottom=[0,0,0,0], $fn=$fn){
    j=[1,0,1,0];

    fn_V = $fn[0] == undef ? $fn : $fn[0];
    fn_T = $fn[1] == undef ? $fn : $fn[1];
    fn_B = $fn[2] == undef ? $fn : $fn[2];

    for (i=[0:3]) {
        if (radius > -1) {
            rotate([0, 0, 90*i]) translate([size[1-j[i]]/2, size[j[i]]/2, 0]) fillet(radius, size[2], fn_V);
        } else {
            rotate([0, 0, 90*i]) translate([size[1-j[i]]/2, size[j[i]]/2, 0]) fillet(vertical[i], size[2], fn_V);
        }
        rotate([90*i, -90, 0]) translate([size[2]/2, size[j[i]]/2, 0 ]) fillet(top[i], size[1-j[i]], fn_T);
        rotate([90*(4-i), 90, 0]) translate([size[2]/2, size[j[i]]/2, 0]) fillet(bottom[i], size[1-j[i]], fn_B);

    }
}

module cube_fillet_inside(size, radius=-1, vertical=[3,3,3,3], top=[0,0,0,0], bottom=[0,0,0,0], $fn=$fn){
    //makes CENTERED cube with round corners
    // if you give it radius, it will fillet vertical corners.
    //othervise use vertical, top, bottom arrays
    //when viewed from top, it starts in upper right corner (+x,+y quadrant) , goes counterclockwise
    //top/bottom fillet starts in direction of Y axis and goes CCW too

    if (radius == 0) {
        cube(size, center=true);
    } else {
        difference() {
            cube(size, center=true);
            cube_negative_fillet(size, radius, vertical, top, bottom, $fn);
        }
    }
}

//cube_fillet([10,10,10]);

// preview[view:northeast, tilt:topdiagonal]

/* [Options] */
// Pit probe type
Control_Probe = "Thermocouple"; // [Thermocouple,Thermistor,None]
// Raspberry Pi Model
Pi_Model = "3B/2B/1B+"; // [3B/2B/1B+,Connectorless,1A+,Zero,3A+]
// Which case halves
Pieces = "Both"; // [Both,Top,Bottom]
// Include cutouts and mounts for LCD/Buttons
LCD = 1; // [0:None,1:2-line]
// Thickness of side walls (mm) - Set to trace width multiple
wall = 2.0;
/* [Advanced] */
// Thickness of top and bottom faces (mm)
wall_t = 1.45;
// Height of the body edge bead chamfer (mm)
body_chamfer_height = 1.5;
// Corner ear height (mm) - 0 to disable
MouseEarHeight = 0;
// Corner leg height (mm) - 0 to disable
MouseLegHeight = 0; //body_chamfer_height/2;

/* [Hidden] */
// External corner radius on the body (mm)
body_corner_radius = wall*2-1/2;
w_off = 0.5; // offset the heatermeter origin from the left edge
d_off = 1.0; // offset the heatermeter origin from the front edge
w = inch(3.725)+0.7+w_off; // overall interior case width
d = inch(3.75)+1.0+d_off; // overall interior case depth
// 19.1+ headless Zero
// 22.4 headless Pi3 (limited by nuttrapps interfering with PCB to -6.7)
// 32 standard
h_b = [32.5-6.7, 32.5][LCD];  // overall interior case height

probe_centerline = 9.3; // case is split along probe centerline on the probe side
case_split = 12.4;  // and the case split on the other 3 sides

pic_ex = 1.7;
lcd_mount_t = 8.2 - (wall_t - 0.8);
pi_screw_t = 2.3;

body_chamfer_height_t = body_chamfer_height;
body_chamfer_height_b = body_chamfer_height;

e = 0.01;
is_jig = 0; // generate a jig for soldering LEDs

function inch(x) = x*25.4;

main();

module main()
{
  if (is_jig) {
    intersection() {
      hm43_split();
      translate([wall+6,-d-wall+3,-e]) cube([w-12,d-8,15]);
    }

    difference() {
      cube([w-12,d-8,8 - wall_t]);
      translate([wall,wall,-e]) cube([w-12-2*wall, d-8-2*wall, 8 - wall_t +2*e]);
    }
  } /* is_jig */
  else
    hm43_split();
}

module cube_fillet_chamfer(size,f,c,$fn=32) {
  hull() {
    translate([f,f,c]) linear_extrude(height=size[2]-2*c) minkowski() {
      square([size[0]-2*f, size[1]-2*f]);
      circle(r=f, $fn=$fn);
    }
    translate([f+c,f+c,0]) linear_extrude(height=size[2]) minkowski() {
      square([size[0]-2*(f+c), size[1]-2*(f+c)]);
      circle(r=f, $fn=$fn);
    }
  }
}

module jhole(d, h) {
  translate([0,0,h/2]) cube([2*(wall+pic_ex),d,h], center=true);
}

module phole() {
  dia=4.5;
  // Hole for thermistor probe jack
  rotate([0,90,0]) cylinder(2*wall, d=dia, $fn=16);
  // because 3d print tends to curl up slightly between the probe holes,
  // do not go right to the edge on the final layer (stop 0.25mm short on each side)
  translate([0,-(dia+0.5)/2, -0.3]) cube([2*wall, dia+0.5, 0.6]);
}

module screwhole() {
  translate([0,0,-e]) cylinder(3.5, d=6, $fn=18);
  translate([0,0,3+0.4]) cylinder(h_b-3.5-0.4+wall_t, d=3.4, $fn=18);
  translate([0.0,0,h_b+wall_t-lcd_mount_t/2-e])
    cylinder(lcd_mount_t/2+e, d=(2.9*2)/sin(60), $fn=6);
}

module pic_ex_cube(interior) {
  translate([0,33.75+interior*(pic_ex+1.3),2])
    cube_fillet([pic_ex+e, 59.8-interior*(pic_ex*2+1.3+1.5), 20.8],
      vertical=[0, (1-interior)*pic_ex, (1-interior)*pic_ex, 0],
      top=[0,pic_ex,0,0],
      bottom=[0,pic_ex,0,0]);
}

module screw_pimount() {
  cylinder(wall_t+pi_screw_t, d=6.4, $fn=18);
  // alignment nubbies
  //cylinder(wall_t+pi_screw_t+1.4, d=2.4, $fn=12);
}

module screw_keyhole() {
  d=6.2;
  d2=3.5;
  off=4.15; // ideally would be D but runs into edge of case
  h=3;

  cylinder(wall_t+2*e, d=d, $fn=18);
  translate([-d2/2,0,0]) cube([d2,off,wall_t+2*e]);
  translate([0,off,0]) {
    cylinder(wall_t+2*e, d=d2, $fn=18);
    translate([0,0,wall_t+e]) cylinder(h+e, d=d, $fn=18);
  }
}

module screw_keyhole_p() {
  d=6.2+wall;
  h=2.3;

  difference() {
    cylinder(wall_t+h, d=d, $fn=18);
    translate([0,0,-e]) cylinder(wall_t+h+2*e, d=d-wall, $fn=18);
    translate([-d,0,-e]) cube([d*2, d/2, wall_t+h+2*e]);
  }
}

module btn_rnd() {
  dia = is_jig ? 6.0 : 7.2;
  cylinder(wall_t+2*e, d1=dia, d2=dia+1.5*wall_t, $fn=24);
  translate([-6.5,-6.5,0]) cube([13,13,0.5+e]);
}

module tc_plusminus() {
  T=0.75+e;
  H=2;
  W=6;
  // Minus
  translate([0,2,0])
    cube_fillet([T, W, H], top=[0,0,0,T]);
  translate([0,-(2+W),0]) {
    cube_fillet([T, W, H], top=[0,0,0,T]);
    translate([0,(W-H)/2,(H-W)/2])
      cube_fillet([T, H, W], top=[0,0,0,T]);
  }
}

module led_hole() {
  dia = is_jig ? 3.2 : 3.4;
  cylinder(wall_t+2*e, d1=dia, d2=dia, $fn=16);
}

module nuttrap() {
  ww_w=3;
  ww_d=wall;
  nut_h=3.2;
  nut_ingress = 5.7;
  nut_d = nut_ingress / sin(60);
  nut_ingress_off = nut_ingress/sqrt(3)/2;
  oa_h=wall_t+0.4+nut_h+wall_t+[0,6.7][LCD];

  // bottom half for M3 socket cap screw (flush)
  difference() {
    translate([-5.5/2-ww_w, -nut_ingress/2-d_off-e, 0])
      cube_fillet([5.5+2*ww_w, nut_ingress+d_off+ww_d, 6], vertical=[3.4,3.4], $fn=20);
    // socket cap
    translate([0,0,-e]) cylinder(3.5, d=6, $fn=18);
    // screw shaft
    translate([0,0,3.5+0.3]) cylinder(oa_h-3, d=3.4, $fn=18);
  }

  // top half M3 nut trap
  translate([0,0,h_b+wall_t-oa_h])
  difference() {
    translate([-(nut_d/2+ww_w), -nut_ingress/2-d_off, 0])
      cube_fillet([nut_d+2*ww_w, nut_ingress+d_off+ww_d, oa_h+e],
        vertical=[ww_d/2,3.4], $fn=20);
    // M3 screw
    translate([0,0,-e]) cylinder(wall_t, d1=4, d2=3.4, $fn=16);
    // nut hole / M3 extra
    translate([0,0,wall_t+0.3]) {
      // nut 2x for an elongated trap
      translate([-0.2,0,0]) cylinder(nut_h*1.5+e, d=nut_d, $fn=6);
      translate([+0.2,0,0]) cylinder(nut_h*1.5+e, d=nut_d, $fn=6);
      cylinder(oa_h-wall_t-0.3, d=4, $fn=16);  // M3 with plenty of clearance
      //translate([-50,-50,-100]) cube([100,100,100+e]); // cutaway top
    }
    // nut ingress (sideways trapezoid with wider side at ingress)
    translate([nut_ingress_off,-nut_ingress/2,wall_t+0.3])
       linear_extrude(nut_h+e) polygon([[0,0],
         [nut_d/2+ww_w-nut_ingress_off+0.4+e, -0.8],
         [nut_d/2+ww_w-nut_ingress_off+0.4+e, nut_ingress+0.8],
         [0,nut_ingress]]);
  }
}

module locklip_p(l, l_offset=0,
  lip_insert_depth=2.0, // how deep V to insert
  lip_v_off=0.2, // extra height before starting insert
  lip_h_off=0.4, // back connector away from mating area
  lip_w=2.5,  // thickness of attachment beam
  insert_inset=[0,0] // inset the insert inside mating area
  ) {
  translate([l_offset,0,0]) rotate([90,0,0]) rotate([0,90,0])
    difference() {
      linear_extrude(height=l-2*l_offset) polygon(points=[
        [0.1, -lip_w-lip_insert_depth-lip_h_off],  // 0.1 to add depth to keep extrusion manifold
        [0.1, 0],
        [-lip_insert_depth-lip_h_off, 0],
        [-lip_insert_depth-lip_h_off, lip_v_off],
        [-lip_h_off, lip_v_off+lip_insert_depth],
        [-lip_insert_depth-lip_h_off, lip_v_off+2*lip_insert_depth,],
        [-lip_w-lip_insert_depth-lip_h_off, lip_v_off+2*lip_insert_depth],
        [-lip_w-lip_insert_depth-lip_h_off, 0]
      ]);
      translate([-lip_w-lip_insert_depth-lip_h_off-e, 0, 0]) {
        if (insert_inset[0] > 0)
          translate([0,0,-e])
            cube([lip_w+lip_insert_depth+lip_h_off+2*e,
              lip_v_off+2*lip_insert_depth+e, insert_inset[0]+e]);
        if (insert_inset[1] > 0)
          translate([0, 0, l-2*l_offset-insert_inset[1]])
            cube([lip_w+lip_insert_depth+lip_h_off+2*e,
              lip_v_off+2*lip_insert_depth+e, insert_inset[1]+e]);
      }
    }
}

module locklip_n(l, l_offset=0,
  lip_insert_depth=2.2, // how deep V to insert
  lip_tip_clip=0.3, // how much to shave off the top tip
  ) {
  translate([l-l_offset,0,0]) rotate([90,0,0]) rotate([0,-90,0])
    linear_extrude(height=l-2*l_offset) polygon(points=[
      [0.1, -3*lip_insert_depth],  // 0.1 to add depth to keep extrusion manifold
      [0.1, -lip_tip_clip],
      [-lip_insert_depth+lip_tip_clip, -lip_tip_clip],
      [-e, -lip_insert_depth],
      [-lip_insert_depth, -2*lip_insert_depth]
    ]);
}

module lcd_screw() {
  rotate([180]) difference() {
    //cylinder(lcd_mount_t, d=2.5+3.2, $fn=16);
    cylinder(lcd_mount_t+e, d=2.5, $fn=16);
  }
}

module lcd_mount() {
  // Assuming starting at bottom left screw hole
  //lcd_screw();
  //translate([75,0,0]) lcd_screw(); // bottom right hole obscured by PCB
  translate([0,31,0]) lcd_screw();
  translate([75,31,0]) lcd_screw();
}

module lcd_neg() {
  // Assuming starting at bottom left screw hole
  // (Note LCD is not centered vertically on PCB, top is 5.15, bottom is 4.55mm)
  translate([1.0, 1.55, 0])
    cube([73.0, 27.3, lcd_mount_t+wall_t-0.8]); // black bezel inset
  translate([5.5, 7.5, 0])
    cube([64.0, 15.4, lcd_mount_t+wall_t+2*e]); // LCD active area
  //translate([4.23, -2.5, 0])
  //  cube([16*2.54, 5, lcd_mount_t+wall_t-0.8]); // pins cutout
}

module locklip_top_n(split) {
  translate([wall, d+wall, split+wall_t+e])
    rotate([180]) {
      locklip_n(28);
      translate([w-34,0,0]) locklip_n(34);
    }
}

module hm_base() {
  cube_bchamfer([w+2*wall, d+2*wall, h_b+2*wall_t],
    r=body_corner_radius, top=body_chamfer_height_t,
    bottom=body_chamfer_height_b, $fn=36);
  // extra thick by Pi connectors
  if (Pi_Model != "Zero" && Pi_Model != "1A+" && Pi_Model != "3A+")
    translate([-pic_ex,wall+d_off,wall_t])
      pic_ex_cube(0);
  // TC +/-
  if (Control_Probe == "Thermocouple")
    translate([w+wall*2-e,wall+d_off+10,wall_t+19]) tc_plusminus();
}

module hm43() {
difference() {
  hm_base();

  // Main cutout
  translate([wall, wall, wall_t])
    cube_fillet([w, d, h_b],
      bottom=[pi_screw_t,pi_screw_t,pi_screw_t,pi_screw_t],
      top=[pi_screw_t,pi_screw_t,pi_screw_t,pi_screw_t],
      vertical=[body_corner_radius/2,body_corner_radius/2,body_corner_radius/2,body_corner_radius/2],
      $fn=[36,4,4]);
  if (Pi_Model != "Zero" && Pi_Model != "1A+" && Pi_Model != "3A+")
    translate([wall-pic_ex+e,wall+d_off,wall_t]) pic_ex_cube(1);

  // Probe jack side
  translate([w+wall*0.5, wall+d_off, wall_t+probe_centerline]) {
    // Probe jacks
    if (Control_Probe == "Thermocouple")
      // TC jack
      translate([0,inch(0.4)-16.5/2,-1.1]) cube([2*wall, 16.5, 6.5]);
    else if (Control_Probe == "Thermistor")
      translate([0,inch(0.28),0]) phole();
    if (Control_Probe != "None") {
      translate([0,inch(0.95)+inch(0.37)*0,0]) phole();
      translate([0,inch(0.95)+inch(0.37)*1,0]) phole();
      translate([0,inch(0.95)+inch(0.37)*2,0]) phole();
    }
  }
  // Pi connector side
  translate([0,wall+d_off,wall_t]) {
    // Pi connectors
    translate([0,0,5]) {
      if (Pi_Model == "3B/2B/1B+") {
        // ethernet
        translate([0,81.5,-0.8]) jhole(15,13);
        translate([0,81.5,-1.8]) jhole(5,5);
        // USB 0+1
        translate([0,62.75,0]) jhole(13,14.8);
        translate([0,44.75,0]) jhole(13,14.8);
      }
    }
    // HeaterMeter connectors
    translate([0,0,0]) {
      // Blower/Servo output
      translate([0,25,1.7]) jhole(16.4,13);
      // HM power jack
      translate([0,inch(0.2),4.2]) jhole(9.4,11);
    }
  }

  // lcd hole
  if (LCD)
    translate([wall+10.375+w_off, wall+d_off+inch(2), h_b+wall_t-lcd_mount_t-e]) lcd_neg();

  // button holes
  if (LCD) translate([wall+inch(1.925)+w_off, wall+d_off+inch(1.15), h_b+wall_t-e]) {
    translate([-inch(1.1)/2,0,0]) btn_rnd();  // left
    translate([inch(1.1)/2,0,0]) btn_rnd();   // right
    translate([0,inch(0.9)/2,0]) btn_rnd();   // up
    translate([0,-inch(0.9)/2,0]) btn_rnd();  // down
    // LED holes
    translate([inch(1.3), inch(-0.05), 0]) {
      led_hole();  //red
      translate([0, inch(0.35), 0]) led_hole(); //yellow
      translate([0, inch(0.70), 0]) led_hole(); //green
    }
  }
  // close screw holes
  translate([wall+inch(0.825)+0.5,wall+d_off+inch(0.1),0]) {
    screwhole();
    translate([inch(2.0),0,0]) screwhole();
  }
  // keyholes
  //translate([wall+24,wall+d_off+39,-e]) {
  //    translate([0,49,0]) screw_keyhole();
  //    translate([58,49,0]) screw_keyhole();
  //}
}  // END OF DIFFERENCE

  // Pi mounting screws
  translate([wall+24,wall+d_off+39,0]) {
    translate([0,0,0]) screw_pimount();
    translate([58,0,0]) screw_pimount();
    if (Pi_Model == "Zero") {
      translate([0,23,0]) screw_pimount();
      translate([58,23,0]) screw_pimount();
    }
    else {
      translate([0,49,0]) screw_pimount();
      translate([58,49,0]) screw_pimount();
      //translate([0,49,0]) screw_keyhole_p();
      //translate([58,49,0]) screw_keyhole_p();
    }
  }

  if (Pi_Model != "Zero") {
    // Pi right edge stop
    translate([wall+w-9.5, wall+d_off+35, wall_t])
      difference() {
        cube_fillet([9.5,d-d_off-35,4], vertical=[0,0,10/2], $fn=24);
        // Pi B+ microsd gap
        translate([-e,22,-e]) cube_fillet([5.5,14.5,4+2*e], vertical=[2,0,0,2], $fn=20);
      }
  } // if !Zero

  // close nut traps
  if (!is_jig) translate([wall+inch(0.825)+w_off,wall+d_off+inch(0.1),0]) {
      nuttrap();
      translate([inch(2.0),0,0]) nuttrap();
    }

  // Top locklip (negative)
  if (Pi_Model == "3B/2B/1B+")
    locklip_top_n(case_split);
  else
    locklip_top_n(probe_centerline);

  // LCD mount
  if (LCD) difference() {
    union() {
      // Filled block above LCD hole
      translate([wall, wall+d_off+78, h_b+wall_t-lcd_mount_t])
        cube([w,d-d_off-78,lcd_mount_t+e]);
      // LCD grab notch
      translate([wall+10.375+w_off, wall+d_off+inch(2), h_b+wall_t-lcd_mount_t])
        translate([(77.5-20)/2,34.0-wall_t,-(1.8+wall_t)])
          // 1.8=thickness of LCD pcb
          cube_fillet([20,1.8+wall_t+wall,1.8+wall_t+e], top=[0,0,1.8+wall_t+e],
            vertical=[wall/2,wall/2]);
    }
    translate([wall+10.375+w_off, wall+d_off+inch(2), h_b+wall_t-e]) {
      translate([0, 0, -lcd_mount_t]) lcd_neg();
      // vv Keep screw holes where they have been since the beginning
      translate([0, 0.5, 0]) lcd_mount();
    }
  }

  if (Pi_Model == "3B/2B/1B+")
    translate([-pic_ex, wall+d_off, wall_t+2]) {
      // USB pillar reinforcements
      translate([0, (44.75+62.75)/2-2.2/2, 1.5])
        cube_fillet([pic_ex+wall, 2.2, 20.8-1.5], bottom=[0,pic_ex,0,2], top=[0,pic_ex]);
      translate([0, 81.5-15/2-3, 1.5])
        cube_fillet([pic_ex+wall, 2.5, 20.8-1.5], bottom=[0,pic_ex,0,2], top=[0,pic_ex]);
    }
}

module lip_guide(l) {
  guide_offset = 0.2; // how much to recess the edge guides
  guide_h = 1.2; // how tall above the edge to extend
  linear_extrude(height=l) polygon([
    [0,-e], [wall+guide_offset,-e], [0, wall+guide_offset],
    [-guide_h, wall+guide_offset], [-guide_h, guide_offset],
    [0, guide_offset]
  ]);
}

module hm43_bottom_lips(split) {
  translate([wall, wall, split+wall_t]) {
    // bottom locklip (positive)
    translate([0,d,0]) {
      locklip_p(28, insert_inset=[2,0]);
      translate([w-34,0,0]) locklip_p(34-wall, insert_inset=[0,1]);
    }

    // front guide lip
    translate([w/2-9, 0, 0])
      rotate([0,90]) lip_guide(25);
    // left guide lip assortment
    translate([0, d_off+5.25+9.4/2, 0])
      rotate([-90]) rotate(90) mirror([0,1,0]) lip_guide(25.25-5.25-9.4/2-16.7/2);
    *translate([-pic_ex, d_off+52, 0])
      rotate([-90]) rotate(90) mirror([0,1,0]) lip_guide(3.5);
    *translate([-pic_ex, d_off+70, 0])
      rotate([-90]) rotate(90) mirror([0,1,0]) lip_guide(3.5);
  }
  // probe side guide lip
  translate([wall+w, wall+d-45, probe_centerline+wall_t])
    rotate([-90]) rotate(90) lip_guide(40);
}

module mouseears() {
  me_h = MouseEarHeight;
  me_d = 20;
  me_overlap = wall;
  me_outset_bottom = (me_d/2 - body_corner_radius/4 - body_chamfer_height_b - me_overlap) * 0.707;
  me_outset_top = (me_d/2 - body_corner_radius/4 - body_chamfer_height_t - me_overlap) * 0.707;

  // Bottom outside corners
  if (Pieces != "Top") {
    translate([-me_outset_bottom, d+2*wall+me_outset_bottom, 0])
      cylinder(me_h, d=me_d, $fn=24);
    translate([w+2*wall+me_outset_bottom, d+2*wall+me_outset_bottom, 0])
      cylinder(me_h, d=me_d, $fn=24);
  }

  // top outside corners
  if (Pieces != "Bottom") {
    translate([0,-1,me_h]) rotate([180]) {
      translate([w+2*wall+me_outset_top, d+2*wall+me_outset_top, 0])
        cylinder(me_h, d=me_d, $fn=24);
      translate([-me_outset_top, d+2*wall+me_outset_top, 0])
        cylinder(me_h, d=me_d, $fn=24);
    }
  }

  // common corner area
  translate([-me_outset_bottom/0.707, 0, 0])
    cylinder(me_h, d=me_d, $fn=24);
  translate([w+2*wall+me_outset_bottom/0.707, 0, 0])
    cylinder(me_h, d=me_d, $fn=24);
}

module mouseleg(isBottom) {
  MouseLegWidth = 2*0.63;
  if (isBottom)
    translate([body_chamfer_height_b+0.3, -MouseLegWidth/2, 0])
      cube([body_corner_radius+body_chamfer_height_b, MouseLegWidth, MouseLegHeight]);
  else
    translate([body_chamfer_height_t+0.3, -MouseLegWidth/2, h_b+2*wall_t-MouseLegHeight])
      cube([body_corner_radius+body_chamfer_height_t, MouseLegWidth, MouseLegHeight]);
}

module mouselegs(isBottom) {
  translate([body_chamfer_height_t+body_corner_radius/2,
    body_chamfer_height_t+body_corner_radius/2, 0])
    rotate(-135) mouseleg(isBottom);
  translate([w+2*wall-body_chamfer_height_t-body_corner_radius/2,
    body_chamfer_height_t+body_corner_radius/2, 0])
    rotate(-45) mouseleg(isBottom);
  translate([w+2*wall-body_chamfer_height_t-body_corner_radius/2,
    d+2*wall-body_chamfer_height_t-body_corner_radius/2, 0])
    rotate(45) mouseleg(isBottom);
  translate([body_chamfer_height_t+body_corner_radius/2,
    d+2*wall-body_chamfer_height_t-body_corner_radius/2, 0])
    rotate(135) mouseleg(isBottom);
}

module split_volume() {
  if (Pi_Model == "3B/2B/1B+") {
    difference() {
      translate([-pic_ex-e,-e,-e])
        cube([w+pic_ex+2*wall+2*e, d+2*wall+2*e, wall_t+case_split+2*e]);
      translate([w,0,wall_t+probe_centerline])
        cube([3*wall, d+2*wall+2*e, wall_t+probe_centerline+2*e]);
    }
  }
  else
    translate([-w,-d,-e])
      cube([3*w, 3*d, wall_t+probe_centerline+2*e]);
}

module hm43_split() {
  // bottom
  if (Pieces != "Top") translate([0,4,0]) {
    intersection() {
      hm43();
      split_volume();
    }
    if (Pi_Model == "3B/2B/1B+")
      hm43_bottom_lips(case_split);
    else
      hm43_bottom_lips(probe_centerline);
    if (MouseLegHeight > 0.0) mouselegs(true);
  } // if include bottom

  // top
  if (Pieces != "Bottom") {
    translate([0,-1,h_b+2*wall_t]) rotate([180]) {
      difference() {
        hm43();
        //translate([11,5,h_b+2*wall_t-0.24]) linear_extrude(0.5)
        //  text("HeaterMeter", font = "Liberation Sans:style=Bold Italic");
        split_volume();
      }
      if (MouseLegHeight > 0.0) mouselegs(false);
    }
  }  // if include top
  if (MouseEarHeight > 0.0)
    color("silver") mouseears();
}

/**********************                               **********************/
/********************** END OF CASE / LIBRARY FOLLOWS **********************/
/**********************                               **********************/

module cube_bchamfer(dim, r, top=0, bottom=0, $fn=$fn) {
  // bottom beaded area
  if (bottom != 0) hull(){
    translate([r,r,0]) cylinder(bottom, r1=r-bottom, r2=r, $fn=$fn);
    translate([dim[0]-r,r,0]) cylinder(bottom, r1=r-bottom, r2=r, $fn=$fn);
    translate([r,dim[1]-r,0]) cylinder(bottom, r1=r-bottom, r2=r, $fn=$fn);
    translate([dim[0]-r,dim[1]-r,0]) cylinder(bottom, r1=r-bottom, r2=r, $fn=$fn);
  }
  // center
  translate([0,0,bottom]) hull(){
    translate([r,r,0]) cylinder(dim[2]-top-bottom, r=r, $fn=$fn);
    translate([dim[0]-r,r,0]) cylinder(dim[2]-top-bottom, r=r, $fn=$fn);
    translate([r,dim[1]-r,0]) cylinder(dim[2]-top-bottom, r=r, $fn=$fn);
    translate([dim[0]-r,dim[1]-r,0]) cylinder(dim[2]-top-bottom, r=r, $fn=$fn);
  }
  // top beaded area
  if (top != 0) translate([0,0,dim[2]-top]) hull(){
    translate([r,r,0]) cylinder(top, r2=r-top, r1=r, $fn=$fn);
    translate([dim[0]-r,r,0]) cylinder(top, r2=r-top, r1=r, $fn=$fn);
    translate([r,dim[1]-r,0]) cylinder(top, r2=r-top, r1=r, $fn=$fn);
    translate([dim[0]-r,dim[1]-r,0]) cylinder(top, r2=r-top, r1=r, $fn=$fn);
  }
}

module fillet(radius, height=100, $fn=$fn) {
  if (radius > 0) {
    //this creates acutal fillet
    translate([-radius, -radius, -height / 2 - 0.02]) difference() {
        cube([radius * 2, radius * 2, height + 0.04]);
        if ($fn == 0 && (radius == 2 || radius == 3 || radius == 4)) {
            cylinder(r=radius, h=height + 0.04, $fn=4 * radius);
        } else {
            cylinder(r=radius, h=height + 0.04, $fn=$fn);
        }

    }
  }
}

module cube_fillet(size, radius=-1, vertical=[0,0,0,0], top=[0,0,0,0], bottom=[0,0,0,0], center=false, $fn=4){
    if (center) {
        cube_fillet_inside(size, radius, vertical, top, bottom, $fn);
    } else {
        translate([size[0]/2, size[1]/2, size[2]/2])
            cube_fillet_inside(size, radius, vertical, top, bottom, $fn);
    }
}

module cube_negative_fillet(size, radius=-1, vertical=[3,3,3,3], top=[0,0,0,0], bottom=[0,0,0,0], $fn=$fn){
    j=[1,0,1,0];

    fn_V = $fn[0] == undef ? $fn : $fn[0];
    fn_T = $fn[1] == undef ? $fn : $fn[1];
    fn_B = $fn[2] == undef ? $fn : $fn[2];

    for (i=[0:3]) {
        if (radius > -1) {
            rotate([0, 0, 90*i]) translate([size[1-j[i]]/2, size[j[i]]/2, 0]) fillet(radius, size[2], fn_V);
        } else {
            rotate([0, 0, 90*i]) translate([size[1-j[i]]/2, size[j[i]]/2, 0]) fillet(vertical[i], size[2], fn_V);
        }
        rotate([90*i, -90, 0]) translate([size[2]/2, size[j[i]]/2, 0 ]) fillet(top[i], size[1-j[i]], fn_T);
        rotate([90*(4-i), 90, 0]) translate([size[2]/2, size[j[i]]/2, 0]) fillet(bottom[i], size[1-j[i]], fn_B);

    }
}

module cube_fillet_inside(size, radius=-1, vertical=[3,3,3,3], top=[0,0,0,0], bottom=[0,0,0,0], $fn=$fn){
    //makes CENTERED cube with round corners
    // if you give it radius, it will fillet vertical corners.
    //othervise use vertical, top, bottom arrays
    //when viewed from top, it starts in upper right corner (+x,+y quadrant) , goes counterclockwise
    //top/bottom fillet starts in direction of Y axis and goes CCW too

    if (radius == 0) {
        cube(size, center=true);
    } else {
        difference() {
            cube(size, center=true);
            cube_negative_fillet(size, radius, vertical, top, bottom, $fn);
        }
    }
}

//cube_fillet([10,10,10]);


This is v1 - 200mm x 200mm with 2mm base thickness

This on took about 12 hours to print using PETG on the Pulse, slow speed (50mm),
30% fill. The print is almost 8" by 8", and there was some detachment/bending. Also 2mm is unnecessarily thick - took the most time to print that 2mm base.

// Cushion Grabber - see README.md for details.
// Author: Joseph M. Joy

function range(stop, start=0,  step=1) = [start: step: stop-1];

// Coords of an isoceles right triangle
function ir_tri(base) = [[0,0], [0, base], [base, 0]];

tri_height = 5;
base_thickness = 2;

// Extruded version
module rt_prism(base, height)  {
    linear_extrude(height) polygon(ir_tri(base));
}

// A row of extruded triangles
module prism_rows(base, height, n) {
    for (i = range(n)) {
         translate([3*base*i, 0, 0]) rt_prism(base, height);
    }
}

// Dome - used for differencing
module dome(width) {
    r = 7;
    ceiling_height = tri_height + base_thickness; // inner height;
    outer_height = r; // height of top of dome from above
    scale([1, ceiling_height/r, 1])
        difference() {
            translate([-r, -r, -r]) cube([width+2*r, 3*outer_height, width+2*r]);
            translate([r, -r, r]) minkowski() {
                cube([width-2*r, r, width-2*r]);
                sphere(r);
            }
        }
}

// Final grabber structure
module cushion_grabber(width) {
    n = width / (3*tri_height); // each row is 3*tri_height, including space
    translate([0, width, 0]) rotate([90, 0, 0])
    difference() {
        union() {
            cube([width, base_thickness, width]);
            translate([tri_height, base_thickness, 0]) prism_rows(tri_height, width, n);
        }
        dome(width);
    }
}

cushion_grabber(200);
//dome(100);

// Cushion Grabber - see README.md for details.
// Author: Joseph M. Joy

function range(stop, start=0,  step=1) = [start: step: stop-1];

// Coords of an isoceles right triangle
function ir_tri(base) = [[0,0], [0, base], [base, 0]];

// Extruded version
module rt_prism(base, height)  {
    linear_extrude(height) polygon(ir_tri(base));
}

// A row of extruded triangles
module prism_rows(base, height, n) {
    for (i = range(n)) {
         translate([2*base*i, 0, 0]) rt_prism(base, height);
    }
}

// Dome - used for differencing
module dome(width) {
    r = 10;
    ceiling_height = 3; // inner height;
    outer_height = r; // height of top of dome from above
    scale([1, ceiling_height/r, 1])
        difference() {
            translate([-r, -r, -r]) cube([width+2*r, 3*outer_height, width+2*r]);
            translate([r, -r, r]) minkowski() {
                cube([width-2*r, r, width-2*r]);
                sphere(r);
            }
        }
}

// Final grabber structure
module cushion_grabber(width) {
    tri_height = 2;
    base_height = 1;
    n = width / (2*tri_height); // each row is 2*tri_height, including space
    translate([0, width, 0]) rotate([90, 0, 0])
    difference() {
        union() {
            cube([width, base_height, width]);
            translate([0, base_height, 0]) prism_rows(tri_height, width, n);
        }
        dome(width);
    }
}

cushion_grabber(50);
//dome(100);


feat: add an operator to animate a translation

/**
 * @license
 * MIT License
 *
 * Copyright (c) 2022 Jean-Sebastien CONAN
 *
 * Permission is hereby granted, free of charge, to any person obtaining a copy
 * of this software and associated documentation files (the "Software"), to deal
 * in the Software without restriction, including without limitation the rights
 * to use, copy, modify, merge, publish, distribute, sublicense, and/or sell
 * copies of the Software, and to permit persons to whom the Software is
 * furnished to do so, subject to the following conditions:
 *
 * The above copyright notice and this permission notice shall be included in all
 * copies or substantial portions of the Software.
 *
 * THE SOFTWARE IS PROVIDED "AS IS", WITHOUT WARRANTY OF ANY KIND, EXPRESS OR
 * IMPLIED, INCLUDING BUT NOT LIMITED TO THE WARRANTIES OF MERCHANTABILITY,
 * FITNESS FOR A PARTICULAR PURPOSE AND NONINFRINGEMENT. IN NO EVENT SHALL THE
 * AUTHORS OR COPYRIGHT HOLDERS BE LIABLE FOR ANY CLAIM, DAMAGES OR OTHER
 * LIABILITY, WHETHER IN AN ACTION OF CONTRACT, TORT OR OTHERWISE, ARISING FROM,
 * OUT OF OR IN CONNECTION WITH THE SOFTWARE OR THE USE OR OTHER DEALINGS IN THE
 * SOFTWARE.
 */

/**
 * Part of the camelSCAD library.
 *
 * Operators that animate child modules with respect to particular rules.
 *
 * @package operator/animate
 * @author jsconan
 */

/**
 * Translates the child modules, interpolating the coordinates with respect to the `$t` variable.
 *
 * @param Vector [from] - The coordinates from where starts the interpolation.
 * @param Vector [to] - The coordinates to where ends the interpolation.
 * @param Number [start] - The start threshold under what the from-coordinates will persist and above what it will be interpolated.
 * @param Number [end] - The end threshold above what the to-coordinates will persist and under what it will be interpolated.
 * @param Number [domain] - The percentage domain used to compute the thresholds (default: 100).
 * @param Vector [values] - A list of coordinates composing the range to interpolate.
 * @param Vector [range] - A pre-built interpolation range. If missing, it will be built from the parameters `from`, `to`, `start`, `end`, `domain`.
 * @returns Number
 */
module translateAnimate(from, to, start, end, domain, values, range) {
    translate(interpolateStep3D(step=$t, low=from, high=to, start=start, end=end, domain=domain, values=values, range=range)) {
        children();
    }
}

error: pathspec 'operator/animate/translate.scad' did not match any file(s) known to git


linear_extrusion: add basic 2020 extrusion module

use <shapes.scad>

module linear_extrusion(h=10, center=true, align=[0,0,0], orient=[0,0,1])
{
    size_align([20,20,h], align, orient)
    {
        linear_extrude(height = h, center = true, convexity = 10, twist = 0)
        {
            import (file = "data/misumi-extrusion/hfs5-2020-profile.dxf");
        }
    }
}

linear_extrusion(h=100, align=[0,0,0], orient=[0,0,1]);

error: pathspec 'linear-extrusion.scad' did not match any file(s) known to git


Add demo for the cushion shape and some helpers

/**
 * Samples using the camelSCAD library.
 *
 * A simple parametric box with rounded corners.
 *
 * @author jsconan
 * @license CC0-1.0
 */

// As we need to use some shapes, use the right entry point of the library
use <../shapes.scad>

/**
 * Renders a rounded box at the origin.
 *
 * @param Vector|Number size - The outer dimensions of the box
 * @param Number thickness - The thickness of the box walls (default 1). Cannot be greater than 10% of the lowest dimension.
 * @param Number radius - The radius of the corner (default 10% of the lowest dimension)
 */
module simpleBox(size, thickness, radius) {
    // Adjust the values to get usable size, thickness, and rounded corner radius
    size = vector3D(size);
    lowest = min(size[0], size[1]) / 10;
    thickness = min(numberOr(thickness, 1), lowest);
    radius = numberOr(radius, lowest);

    // Compute the size and position of the handle hole
    handleRadius = size[0] + size[1];
    handleCenter = center2D(
        a=apply2D(x=-size[0] / 2 + radius, y=size[2]),
        b=apply2D(x=size[0] / 2 - radius, y=size[2]),
        r=handleRadius,
        negative=true
    );

    difference() {
        // This is the outside of the box
        cushion(size=size, r=radius);

        // This is the inside of the box
        translate([0, 0, thickness]) {
            cushion(size=apply3D(size, x=size[0] - thickness * 2, y=size[1] - thickness * 2), r=radius-thickness/2);
        }

        // This is the handle hole
        rotateX(90) {
            translate(vector3D(handleCenter)) {
                cylinder(r=handleRadius, h=size[1] + 1, center=true);
            }
        }
    }

}

// We will render the object using the specifications of this mode
renderMode = "prod";

// Defines the dimensions of the box
length = 100;
width = 70;
height = 40;
thickness = 1;
radius = 5;

// Sets the minimum facet angle and size using the defined render mode.
$fa = facetAngle(renderMode);
$fs = facetSize(renderMode);

// And draw the box accordingly
simpleBox(size = [length, width, height], thickness=thickness, radius=radius);

// You may also draw a cover by rendering another box that has an increased size with respect to the wall thickness...
%translate([0, 0, height + thickness]) {
    rotateX(180) {
        // Use an additional adjustment value (0.1) to counter the printer's precision lack and
        // allow to put the cover in place once printed.
        sizeAdjust = thickness * 2 + 0.1;
        simpleBox(size = [length + sizeAdjust, width + sizeAdjust, height + thickness], thickness=thickness, radius=radius);
    }
}

error: pathspec 'samples/simple-box.scad' did not match any file(s) known to git


made lit a bit bigger, with more rounded corners

// unified payload electronics mount

Bhole=2.38+.3;  // for brass tube
PCBhole = (25.4*3/32)/2;//1;  // found that 3/32" drill made good pilot for #4 self-piloting screw
include <JansenDefs.scad>;  // Bx
PCBholeSep=37;  // hole pattern for L298 module is a square this wide
PCBholeInset=15;  // from hole center to side of mount

thinWall=.35;//0.41;  // width of thinnest wall which will not get culled by slicer

//translate([0,20,0]) L298mount();

%translate([0,0,  7.8])                 payloadPlatform();
%translate([0,0,-31.5]) rotate([180,0,0]) lowerPlatform();

braceSep = PCBholeInset+PCBholeSep/2;
for(a=[0,180]) rotate([0,0,a]) translate([0,braceSep,0]) rotate([90,0,0])
      payloadBrace();

translate([0,0,9]) lid();

//translate([0,100,0]) payloadBrace();

//%translate([0,0,-29]) cylinder(r=4,h=31,$fn=4);

// -----------------------------------------------------

module payloadBrace() difference() {
   payloadMount(Bx,Bhole);

   #for(x=[-1,1]) translate([x*Bx,0,-1]) cylinder(r=Bhole,h=44,$fn=25);
   translate([0,0,-4]) cube([200,200,8],center=true);
}

// dovetail tabs for platform
tabZ=4.2;  // offset for tab
module tab(pilotHoleRad=0) difference() {
  cylinder(r1=7,r2=5.5,h=6,$fn=3);

  if (pilotHoleRad > 0.2) {
     translate([0,0,1]) // pilot hole for plastic screw
        #cylinder(r1=pilotHoleRad-.4,r2=pilotHoleRad+.2,h=6,$fn=13);
  }
}
tabCutoutScale = .4/6 + 1;  // want .2 mm space
tabShellScale  =  4/6 + 1;  // want  2 mm space
tabSepUpper=40;
tabSepLower=23;

module payloadPlatform() {
platWidth=100;
  difference() {
    payloadPlatformShell(  platWidth,tabSepUpper); // width, tab seperation
    payloadPlatformCutouts(platWidth,tabSepUpper);
  }
}
module lowerPlatform() {
platWidth=70;
hc=PCBholeSep/2;  // dist for L298N module sqare hole pattern
  difference() {
    payloadPlatformShell(  platWidth,tabSepLower); // width, tab seperation
    difference() {
      payloadPlatformCutouts(platWidth,tabSepLower);
      for(x=[-1,1]) for(y=[-1,1]) translate([x*hc,y*hc,0])
         cylinder(r1=4,r2=3,h=6,$fn=12,center=true);
    }

    // pilot holes for L298N module mount screws
    for(x=[-1,1]) for(y=[-1,1]) translate([x*hc,y*hc,-1])
       cylinder(r1=PCBhole+.3,r2=PCBhole-.2,h=4,$fn=12,center=true);
  }
}

module payloadPlatformCutouts(width=100,tabSep=40) {
  intersection() {
    difference() {
      hull() for(x=[-1,1]) for(y=[-1,1])
         translate([x*(width/2-5),y*(braceSep-5),0])
            cylinder(r1=2,r2=3,h=6,$fn=16,center=true);

      // cutouts for dovetail tabs
      for(a=[0,180]) rotate([0,0,a])
         for(x=[-tabSep,0,tabSep]) translate([x,braceSep-tabZ,-3])
            rotate([0,0,-30]) scale(tabShellScale) tab();
    }
    hexGrid();
  }
}

dh=3.1;
c30=cos(30);   dx=3*dh;  dy=2*c30*dh;
module hexGrid() {
  translate([3*dh/2,-c30*dh,0])
    for(j=[-5:6]) for(i=[-5:4]) hex(i*dx,j*dy);
    for(j=[-6:6]) for(i=[-5:5]) hex(i*dx,j*dy);
}
module hex(x,y,s=[1,1,1]) translate([x,y,0]) scale(s)
   cylinder(r1=2,r2=2.7,h=6,$fn=6,center=true);

module lid() {
  difference() {
    union() {
      for (i=[-1,1]) for (j=[-1,1])
        hex(3*dx*i,5*dy*j,[.9,.9,1]);
      difference() {
        lidShell();
        translate([0,0,0.3]) scale([.987,.98,.97]) lidShell();
      }
    }
    hull() {
       translate([0,0,3.5]) cube([89,57.5,.1],center=true);
       cube([86,52,7],center=true);
    }

    for(x=[-1,1]) translate([x*23,0,2.2]) rotate([90,0,0])
       scale([2.5,1.5,1]) cylinder(r=1,h=77,$fn=16,center=true);

    //translate([0,0,-99]) cube([200,200,200]);
  }

}

module lidShell()
  hull() {
    for (x=[-1,1]) for(y=[-1,1]) {
      translate([44*x,27.5*y,4.6]) sphere(3,$fn=24);
      translate([40*x,23  *y,30 ]) sphere(3,$fn=24);
    }
}

// width of platform along axes  (Y width fixed)
// tabSep  -- seperation between tab centers
module payloadPlatformShell(width=100,tabSep=40) {
  intersection() {
    difference() {
      cube([width,2*braceSep,5],center=true);

      // slots for dovetail tabs
      for(a=[0,180]) rotate([0,0,a])
         for(x=[-tabSep,0,tabSep]) translate([x,braceSep-tabZ,-3])
            rotate([0,0,-30]) scale(tabCutoutScale) tab();
    }

    // round off corners
    hull()for(x=[-1,1])for(y=[-1,1])translate([x*(width/2-4),y*(braceSep-4),0])
       scale([4.5,4.5,3.5])sphere(1,$fn=36);
  }
}

module L298mount() intersection() { cube([59,99,4],center=true);

  difference() {
    hull() for(x=[-1,1]) for(y=[-1,PCBholeInset-0.5])
       translate([x*(30-4),y,0])
          scale([4,4,3]) sphere(1,$fn=24);

    hull() {
       translate([0,12,0]) scale([ 9,4,6]) sphere(1,$fn=48);
       translate([0,22,0]) scale([18,1,8]) sphere(1,$fn=48);
    }

    difference() {
      union() {
        translate([0,4,0]) scale([ 5,2.5,5]) sphere(1,$fn=24);

        for(x=[-1,1]) {
          translate([x*PCBholeSep/2,PCBholeInset,-4])
            #cylinder(r=PCBhole,h=9,$fn=15);

          for (y=[6,14]) translate([x*26,y,-4]) cylinder(r=1.6,h=9,$fn=15);

          hull() {
            translate([x*21,7,0]) rotate([0,0,40*x])
                scale([5,1,5]) sphere(1,$fn=36);
            translate([x*22,13,0]) scale([1,2,5]) sphere(1,$fn=16);
          }
          hull() {
            translate([x*11,5,0]) rotate([0,0,30*x])
               scale([4,2,5]) sphere(1,$fn=36);
            translate([x*16,12,0]) scale([2,1,5]) sphere(1,$fn=12);
          }

        }
      }

      cube([99,99,thinWall],center=true); // leave support wall
    }
  }
}

module payloadMount(axisSep,axisRad) {
platOff=-30+2;  // L286 module mount platform offset
    union() {

      for (x=[-1,1]) translate([x*axisSep,0,0])    // axle hubs
           cylinder(r1=axisRad+3,r2=axisRad+2,h=12,$fn=36);

      hull() { // top bar
        translate([0,4.7,4]) cube([2*axisSep,.7,8],center=true);
        translate([0,1.5,0]) cube([2*axisSep,1 ,1],center=true);
      }
      hull() for(x=[-1,1]) translate([axisSep*x,1.1,0.5])
            scale([1,4,1.5]) sphere(1,$fn=16);

      hull() { // lower bar
        translate([0,platOff-.7,4]) cube([60,.6,8],center=true);
        translate([0,platOff+1 ,0]) cube([60,1 ,1],center=true);
      }
      hull() for(x=[-1,1]) translate([31*x,platOff+3,0.3])
            rotate([0,0,-x*40]) scale([1,3.5,1.5]) sphere(1,$fn=16);

      //%translate([0,platOff,0]) rotate([90,0,0]) L298mount();

      for(x=[-1,1]) {  // main side braces
        hull() {
          translate([x*(axisSep+2),-2,2]) scale([1.5,1,9]) sphere(1,$fn=16);
          translate([x*29,platOff ,3]) scale([.5,1,4]) sphere(1,$fn=16);
        }
        hull() {
          translate([x*(axisSep-1),0 ,0.3]) scale([4,1,1.5]) sphere(1,$fn=16);
          translate([x*26,platOff,0.3]) scale([3,1,1.5]) sphere(1,$fn=16);
        }
      }

      // upper platform tabs
      for(x=[-tabSepUpper,0,tabSepUpper]) translate([x,5-1,tabZ])
         rotate([-90,0,0]) rotate([0,0,-30]) tab(PCBhole);

      // lower platform tabs
      for(x=[-tabSepLower,0,tabSepLower]) translate([x,platOff+0.3,tabZ])
         rotate([90,0,0]) rotate([0,0,30]) tab(PCBhole);
    }
}

// unified payload electronics mount

Bhole=2.38+.3;  // for brass tube
PCBhole = (25.4*3/32)/2;//1;  // found that 3/32" drill made good pilot for #4 self-piloting screw
include <JansenDefs.scad>;  // Bx
PCBholeSep=37;  // hole pattern for L298 module is a square this wide
PCBholeInset=15;  // from hole center to side of mount

thinWall=.35;//0.41;  // width of thinnest wall which will not get culled by slicer

//translate([0,20,0]) L298mount();

%translate([0,0,  7.8])                 payloadPlatform();
%translate([0,0,-31.5]) rotate([180,0,0]) lowerPlatform();

braceSep = PCBholeInset+PCBholeSep/2;
for(a=[0,180]) rotate([0,0,a]) translate([0,braceSep,0]) rotate([90,0,0])
      payloadBrace();

//translate([0,100,0]) payloadBrace();

//%translate([0,0,-29]) cylinder(r=4,h=31,$fn=4);

// -----------------------------------------------------

module payloadBrace() difference() {
   payloadMount(Bx,Bhole);

   #for(x=[-1,1]) translate([x*Bx,0,-1]) cylinder(r=Bhole,h=44,$fn=25);
   translate([0,0,-4]) cube([200,200,8],center=true);
}

// dovetail tabs for platform
tabZ=4.2;  // offset for tab
module tab(pilotHoleRad=0) difference() {
  cylinder(r1=7,r2=5.5,h=6,$fn=3);

  if (pilotHoleRad > 0.2) {
     translate([0,0,1]) // pilot hole for plastic screw
        #cylinder(r1=pilotHoleRad-.4,r2=pilotHoleRad+.2,h=6,$fn=13);
  }
}
tabCutoutScale = .4/6 + 1;  // want .2 mm space
tabShellScale  =  4/6 + 1;  // want  2 mm space
tabSepUpper=40;
tabSepLower=23;

module payloadPlatform() {
platWidth=100;
  difference() {
    payloadPlatformShell(  platWidth,tabSepUpper); // width, tab seperation
    payloadPlatformCutouts(platWidth,tabSepUpper);
  }
}
module lowerPlatform() {
platWidth=70;
hc=PCBholeSep/2;  // dist for L298N module sqare hole pattern
  difference() {
    payloadPlatformShell(  platWidth,tabSepLower); // width, tab seperation
    difference() {
      payloadPlatformCutouts(platWidth,tabSepLower);
      for(x=[-1,1]) for(y=[-1,1]) translate([x*hc,y*hc,0])
         cylinder(r1=4,r2=3,h=6,$fn=12,center=true);
    }

    // pilot holes for L298N module mount screws
    for(x=[-1,1]) for(y=[-1,1]) translate([x*hc,y*hc,-1])
       cylinder(r1=PCBhole+.3,r2=PCBhole-.2,h=4,$fn=12,center=true);
  }
}

module payloadPlatformCutouts(width=100,tabSep=40) {
  intersection() {
    difference() {
      hull() for(x=[-1,1]) for(y=[-1,1])
         translate([x*(width/2-5),y*(braceSep-5),0])
            cylinder(r1=2,r2=3,h=6,$fn=16,center=true);

      // cutouts for dovetail tabs
      for(a=[0,180]) rotate([0,0,a])
         for(x=[-tabSep,0,tabSep]) translate([x,braceSep-tabZ,-3])
            rotate([0,0,-30]) scale(tabShellScale) tab();
    }
    hexGrid();
  }
}

module hexGrid() {
dh=3.1;
c30=cos(30);  $fn=6;   dx=3*dh;  dy=2*c30*dh;
  translate([3*dh/2,-c30*dh,0])
    for(j=[-5:6]) for(i=[-5:4]) hex(i*dx,j*dy);
    for(j=[-6:6]) for(i=[-5:5]) hex(i*dx,j*dy);
}
module hex(x,y) translate([x,y,0])
   cylinder(r1=2,r2=2.7,h=6,$fn=6,center=true);

// width of platform along axes  (Y width fixed)
// tabSep  -- seperation between tab centers
module payloadPlatformShell(width=100,tabSep=40) {
  intersection() {
    difference() {
      cube([width,2*braceSep,5],center=true);

      // slots for dovetail tabs
      for(a=[0,180]) rotate([0,0,a])
         for(x=[-tabSep,0,tabSep]) translate([x,braceSep-tabZ,-3])
            rotate([0,0,-30]) scale(tabCutoutScale) tab();
    }

    // round off corners
    hull()for(x=[-1,1])for(y=[-1,1])translate([x*(width/2-4),y*(braceSep-4),0])
       scale([4.5,4.5,3.5])sphere(1,$fn=36);
  }
}

module L298mount() intersection() { cube([59,99,4],center=true);

  difference() {
    hull() for(x=[-1,1]) for(y=[-1,PCBholeInset-0.5])
       translate([x*(30-4),y,0])
          scale([4,4,3]) sphere(1,$fn=24);

    hull() {
       translate([0,12,0]) scale([ 9,4,6]) sphere(1,$fn=48);
       translate([0,22,0]) scale([18,1,8]) sphere(1,$fn=48);
    }

    difference() {
      union() {
        translate([0,4,0]) scale([ 5,2.5,5]) sphere(1,$fn=24);

        for(x=[-1,1]) {
          translate([x*PCBholeSep/2,PCBholeInset,-4])
            #cylinder(r=PCBhole,h=9,$fn=15);

          for (y=[6,14]) translate([x*26,y,-4]) cylinder(r=1.6,h=9,$fn=15);

          hull() {
            translate([x*21,7,0]) rotate([0,0,40*x])
                scale([5,1,5]) sphere(1,$fn=36);
            translate([x*22,13,0]) scale([1,2,5]) sphere(1,$fn=16);
          }
          hull() {
            translate([x*11,5,0]) rotate([0,0,30*x])
               scale([4,2,5]) sphere(1,$fn=36);
            translate([x*16,12,0]) scale([2,1,5]) sphere(1,$fn=12);
          }

        }
      }

      cube([99,99,thinWall],center=true); // leave support wall
    }
  }
}

module payloadMount(axisSep,axisRad) {
platOff=-30+2;  // L286 module mount platform offset
    union() {

      for (x=[-1,1]) translate([x*axisSep,0,0])    // axle hubs
           cylinder(r1=axisRad+3,r2=axisRad+2,h=12,$fn=36);

      hull() { // top bar
        translate([0,4.7,4]) cube([2*axisSep,.7,8],center=true);
        translate([0,1.5,0]) cube([2*axisSep,1 ,1],center=true);
      }
      hull() for(x=[-1,1]) translate([axisSep*x,1.1,0.5])
            scale([1,4,1.5]) sphere(1,$fn=16);

      hull() { // lower bar
        translate([0,platOff-.7,4]) cube([60,.6,8],center=true);
        translate([0,platOff+1 ,0]) cube([60,1 ,1],center=true);
      }
      hull() for(x=[-1,1]) translate([31*x,platOff+3,0.3])
            rotate([0,0,-x*40]) scale([1,3.5,1.5]) sphere(1,$fn=16);

      //%translate([0,platOff,0]) rotate([90,0,0]) L298mount();

      for(x=[-1,1]) {  // main side braces
        hull() {
          translate([x*(axisSep+2),-2,2]) scale([1.5,1,9]) sphere(1,$fn=16);
          translate([x*29,platOff ,3]) scale([.5,1,4]) sphere(1,$fn=16);
        }
        hull() {
          translate([x*(axisSep-1),0 ,0.3]) scale([4,1,1.5]) sphere(1,$fn=16);
          translate([x*26,platOff,0.3]) scale([3,1,1.5]) sphere(1,$fn=16);
        }
      }

      // upper platform tabs
      for(x=[-tabSepUpper,0,tabSepUpper]) translate([x,5-1,tabZ])
         rotate([-90,0,0]) rotate([0,0,-30]) tab(PCBhole);

      // lower platform tabs
      for(x=[-tabSepLower,0,tabSepLower]) translate([x,platOff+0.3,tabZ])
         rotate([90,0,0]) rotate([0,0,30]) tab(PCBhole);
    }
}


limit to one axis worth of brackets, and make brackets L-R universal.

$fn=100;

mm=1;

switch_z=10*mm;

base_x=32*mm;
base_y=28*mm;
base_z=3.25*mm;

layer2_z=7.6*mm-base_z;

riser_x=22*mm;
riser_y=base_y;
riser_z=layer2_z;

riser_x_off=0;
riser_y_off=0;
riser_z_off=base_z;

hole_r=2.9*mm/2;
hole_z=base_z + layer2_z;

hole_y_off=1.4*mm + hole_r;

hole1_x_off=11.6*mm + hole_r;
hole2_x_off=hole_y_off;

hole1_L_y_off=hole_y_off;
hole2_L_y_off=base_y-hole_y_off;

hole1_R_y_off=base_y-hole_y_off;
hole2_R_y_off=hole_y_off;

tab_x=2.8*mm;
tab_y=12.5*mm;
tab_z=layer2_z + 3;

tab_x_off=riser_x+3.6*mm + (tab_x/2);
tab_y_off=(base_y-tab_y)/2;
tab_z_off=base_z;

module base(){
   cube([base_x, base_y, base_z]);
}

module tab(x_off, y_off, z_off, x, y, z){
	hull(){
		translate([x_off, y_off, z_off])
			cylinder(d=x, h=z);
		translate([x_off, y_off+(y), z_off])
			cylinder(d=x, h=z);
	}
}

module layer2(){
	translate([riser_x_off, riser_y_off, riser_z_off])
		cube([riser_x, riser_y, riser_z]);
}

module bottom_holes(){
	union(){
		translate([hole1_x_off, hole1_L_y_off, 0])
			cylinder(r=hole_r, h=hole_z);
		translate([hole2_x_off, hole2_L_y_off, 0])
			cylinder(r=hole_r, h=hole_z);

		translate([hole1_x_off, hole1_R_y_off, 0])
			cylinder(r=hole_r, h=hole_z);
		translate([hole2_x_off, hole2_R_y_off, 0])
			cylinder(r=hole_r, h=hole_z);

		translate([tab_x_off, tab_y_off, 0])
			cylinder(r=hole_r,h=base_z);
		translate([tab_x_off, tab_y_off+tab_y-hole_r, 0])
			cylinder(r=hole_r,h=base_z);
	}
}

module bracket(){
	difference(){
		union(){
		   	base();
   			layer2();
		}
		bottom_holes();
	}
}

module axis_brackets(){
	bracket();
	translate([0,-(base_y+10),0]) bracket();
}

union(){
    axis_brackets();
//    translate([-(base_x+10),0,0]) axis_brackets();
}

$fn=100;

mm=1;

switch_z=10*mm;

base_x=32*mm;
base_y=28*mm;
base_z=3.25*mm;

layer2_z=7.6*mm-base_z;

riser_x=22*mm;
riser_y=base_y;
riser_z=layer2_z;

riser_x_off=0;
riser_y_off=0;
riser_z_off=base_z;

hole_r=2.9*mm/2;
hole_z=base_z + layer2_z;

hole_y_off=1.4*mm + hole_r;

hole1_x_off=11.6*mm + hole_r;
hole1_y_off=base_y-hole_y_off;

hole2_x_off=hole_y_off;
hole2_y_off=hole_y_off;

tab_x=2.8*mm;
tab_y=12.5*mm;
tab_z=layer2_z + 3;

tab_x_off=riser_x+3.6*mm + (tab_x/2);
tab_y_off=(base_y-tab_y)/2;
tab_z_off=base_z;

module base(){
   cube([base_x, base_y, base_z]);
}

module tab(x_off, y_off, z_off, x, y, z){
	hull(){
		translate([x_off, y_off, z_off])
			cylinder(d=x, h=z);
		translate([x_off, y_off+(y), z_off])
			cylinder(d=x, h=z);
	}
}

module layer2(){
	translate([riser_x_off, riser_y_off, riser_z_off])
		cube([riser_x, riser_y, riser_z]);
}

module bottom_holes(){
	union(){
		translate([hole1_x_off, hole1_y_off, 0])
			cylinder(r=hole_r, h=hole_z);
		translate([hole2_x_off, hole2_y_off, 0])
			cylinder(r=hole_r, h=hole_z);
		translate([tab_x_off, tab_y_off, 0])
			cylinder(r=hole_r,h=base_z);
		translate([tab_x_off, tab_y_off+tab_y-hole_r, 0])
			cylinder(r=hole_r,h=base_z);
	}
}

module bracket(){
	difference(){
		union(){
		   	base();
   			layer2();
		}
		bottom_holes();
	}
}

union(){
	bracket();
	translate([0,-(base_y+10),0]) bracket();
	translate([-(base_x+10),0,0]) bracket();
	translate([-(base_x+10),-(base_y+10),0]) bracket();
}


added mount point

added mount point