Parametric project box

project-box.scad

inside_width=57;
inside_length=48;
inside_height=27;

wall_thickness=1.5;
floor_thickness=1;
overlap_thickness=1.5;
overlap_delta=0.25;

pcb_level=16;
pcb_thickness=1.6;

screw_sep_x=35;
screw_sep_y=37;

screw_int_r=2.5;
screw_ext_r=4;
screw_depth=4;
screw_ledge_depth=0.5;
screw_ledge_r=3;

spacer_int_r=2;
spacer_ext_r=3;

// S: ok, things are starting to get very project-specific now
board_width=45;
board_height=45;
    
screen_offset_x=3;
screen_width=10;
screen_height=25.4;
            
button_offset_x=25.5;
button_offset_y=5.5;
button_offset_z=5;
bh=inside_height-pcb_level-button_offset_z;
button_int_r_min=2.0;
button_int_r_max=3.4;
button_ext_r_min=2.6;
button_ext_r_max=4.0;
button_sup_r=5.5;

module screw()
{
    difference()
    {
        cylinder(pcb_level, screw_ext_r, screw_ext_r, $fn=32);
        translate([0, 0, pcb_level - screw_depth - screw_ledge_depth])
            cylinder(screw_depth, screw_int_r, screw_int_r, $fn=24);
        translate([0, 0, pcb_level - screw_ledge_depth])
            cylinder(screw_ledge_depth, screw_ledge_r, screw_ledge_r, $fn=24);
    }
}

module box()
{
    // coordinate space puts (0, 0, 0) just inside the box
    difference()
    {
        translate([-wall_thickness, -wall_thickness, -floor_thickness])
        {
            cube([inside_width + wall_thickness*2,
                  inside_length + wall_thickness*2,
                  inside_height + floor_thickness]);
        }
        cube([inside_width, inside_length, inside_height]);
    }
    translate([inside_width/2 - screw_sep_x/2, inside_length/2 - screw_sep_y/2, 0])
        screw();
    translate([inside_width/2 - screw_sep_x/2, inside_length/2 + screw_sep_y/2, 0])
        screw();
    translate([inside_width/2 + screw_sep_x/2, inside_length/2 - screw_sep_y/2, 0])
        screw();
    translate([inside_width/2 + screw_sep_x/2, inside_length/2 + screw_sep_y/2, 0])
        screw();   
    
}

module lid()
{
    difference()
    {
        union()
        {
            // top
            translate([-wall_thickness, -wall_thickness, -floor_thickness])
            {
                cube([inside_width + wall_thickness*2,
                      inside_length + wall_thickness*2,
                      floor_thickness]);
            }
            // lip
            translate([overlap_delta, overlap_delta, 0])
            {
                difference()
                {
                    cube([inside_width - overlap_delta*2,
                          inside_length - overlap_delta*2,
                          overlap_thickness]);
                    translate([wall_thickness, wall_thickness, 0])
                    {
                        cube([inside_width - overlap_delta*2 - wall_thickness*2,
                              inside_length - overlap_delta*2 - wall_thickness*2,
                              overlap_thickness]);
                    }
                }
            }
            // spacer ext
            h = inside_height - pcb_level - pcb_thickness;
            translate([inside_width/2 - screw_sep_x/2, inside_length/2 - screw_sep_y/2, 0])
                cylinder(h, spacer_ext_r, spacer_ext_r, $fn=32);
            translate([inside_width/2 - screw_sep_x/2, inside_length/2 + screw_sep_y/2, 0])
                cylinder(h, spacer_ext_r, spacer_ext_r, $fn=32);
            translate([inside_width/2 + screw_sep_x/2, inside_length/2 - screw_sep_y/2, 0])
                cylinder(h, spacer_ext_r, spacer_ext_r, $fn=32);
            translate([inside_width/2 + screw_sep_x/2, inside_length/2 + screw_sep_y/2, 0])
                cylinder(h, spacer_ext_r, spacer_ext_r, $fn=32);
            
            // button support
            translate([inside_width/2 - board_width/2 + button_offset_x,
                       inside_length/2 - board_height/2 + button_offset_y,
                       0])
                cylinder(bh - wall_thickness, button_sup_r, button_sup_r, $fn=24);
            
        }
        union()
        {
            // spacer int (these go all the way through the top)
            h = floor_thickness + inside_height - pcb_level - pcb_thickness;
            translate([inside_width/2 - screw_sep_x/2, inside_length/2 - screw_sep_y/2, -floor_thickness])
                cylinder(h, spacer_int_r, spacer_int_r, $fn=24);
            translate([inside_width/2 - screw_sep_x/2, inside_length/2 + screw_sep_y/2, -floor_thickness])
                cylinder(h, spacer_int_r, spacer_int_r, $fn=24);
            translate([inside_width/2 + screw_sep_x/2, inside_length/2 - screw_sep_y/2, -floor_thickness])
                cylinder(h, spacer_int_r, spacer_int_r, $fn=24);
            translate([inside_width/2 + screw_sep_x/2, inside_length/2 + screw_sep_y/2, -floor_thickness])
                cylinder(h, spacer_int_r, spacer_int_r, $fn=24);
            
            // S: screen window
            translate([inside_width/2 - board_width/2 + screen_offset_x,
                       inside_length/2 - screen_height / 2,
                       -floor_thickness])
                cube([10, 25, floor_thickness]);
            
            // S: button hole
            translate([inside_width/2 - board_width/2 + button_offset_x,
                       inside_length/2 - board_height/2 + button_offset_y,
                       -floor_thickness])
                cylinder(bh/3, button_ext_r_max, button_ext_r_min, $fn=24);
            translate([inside_width/2 - board_width/2 + button_offset_x,
                       inside_length/2 - board_height/2 + button_offset_y,
                       bh/3 - floor_thickness])
                cylinder(bh/3, button_ext_r_min, button_ext_r_min, $fn=24);
            translate([inside_width/2 - board_width/2 + button_offset_x,
                       inside_length/2 - board_height/2 + button_offset_y,
                       2*bh/3 - floor_thickness])
                cylinder(bh/3, button_ext_r_min, button_ext_r_max, $fn=24);
        }
    }
                
    // S: button
    translate([inside_width/2 - board_width/2 + button_offset_x,
               inside_length/2 - board_height/2 + button_offset_y,
               -floor_thickness])
        cylinder(bh/3, button_int_r_max, button_int_r_min, $fn=24);
    translate([inside_width/2 - board_width/2 + button_offset_x,
               inside_length/2 - board_height/2 + button_offset_y,
               bh/3 - floor_thickness])
        cylinder(bh/3, button_int_r_min, button_int_r_min, $fn=24);
    translate([inside_width/2 - board_width/2 + button_offset_x,
               inside_length/2 - board_height/2 + button_offset_y,
               2*bh/3 - floor_thickness])
        cylinder(bh/3, button_int_r_min, button_int_r_max, $fn=24);

}

box();

translate([inside_width+4*wall_thickness,0,0])
    lid();