2-manifold my ass

1 files changed, 61 insertions, 32 deletions

diff --git a/case/top.scad b/case/top.scad
index 1e4aa45..9609e2b 100644
--- a/case/top.scad
+++ b/case/top.scad
@@ -32,19 +32,23 @@ module top_case(key_switch_sizes, pcb_screw_holes) {
 
     support_width = 1.2500;
 
-    screw_post_diameter_inner =  3.00;
-    screw_post_diameter_outer =  6.25;
-    screw_post_corner_height  = 12.00;
-    screw_post_middle_height  = 29.30;
-    screw_post_upper_y_offset = case_length_bottom - wall_width - 15.00;
-    screw_post_x_offset       = wall_width + 6.50;
+    screw_post_diameter_inner  =  3.00;
+    screw_post_diameter_outer  =  6.25;
+    screw_post_corner_height   = 12.00;
+    screw_post_middle_height   = 29.30;
+    screw_post_upper_y_offset  = case_length_bottom - wall_width - 15.00;
+    screw_post_middle_y_offset = 72.50;
+    screw_post_lower_y_offset  =  6.50;
+    screw_post_x_offset        = (keyboard_x_offset - 2 * wall_width) / 2 + wall_width;
+
+    eps = 0.01;
 
     module fascia() {
-        linear_extrude(wall_width)
         difference() {
-            square([case_width_bottom, case_length_bottom], false);
-            translate([keyboard_x_offset, keyboard_y_offset, 0])
-            square([keyboard_width, keyboard_length], false);
+            cube([case_width_bottom, case_length_bottom, wall_width], false);
+
+            translate([keyboard_x_offset, keyboard_y_offset, -eps])
+            cube([keyboard_width, keyboard_length, wall_width + 2*eps], false);
         }
     }
 
@@ -52,24 +56,24 @@ module top_case(key_switch_sizes, pcb_screw_holes) {
         for (i = [0:vent_count]) {
             x = vent_x_first + (i * (vent_width + vent_width));
 
-            translate([x, vent_y_offset, wall_height - vent_height])
-            cube([vent_width, vent_length, vent_height], false);
+            translate([x, vent_y_offset-eps, wall_height - vent_height])
+            cube([vent_width, vent_length+2*eps, vent_height+eps], false);
         }
     }
 
     module accents() {
         for (y = [accent_y_bottom: accent_y_stride: case_length_bottom]) {
             /* Top */
-            translate([0, y, wall_height - accent_depth])
-            cube([case_width_bottom, accent_width, accent_depth], false);
+            translate([-eps, y, wall_height - accent_depth])
+            cube([case_width_bottom+2*eps, accent_width, accent_depth+eps], false);
 
             /* Right */
-            translate([case_width_bottom - accent_depth, y, 0])
-            cube([accent_depth, accent_width, wall_height], false);
+            translate([case_width_bottom - accent_depth, y, -eps])
+            cube([accent_depth+eps, accent_width+eps, wall_height+2*eps], false);
 
             /* Left */
-            translate([0, y, 0])
-            cube([accent_depth, accent_width, wall_height], false);
+            translate([-eps, y, -eps])
+            cube([accent_depth+eps, accent_width, wall_height+2*eps], false);
         }
     }
 
@@ -78,8 +82,33 @@ module top_case(key_switch_sizes, pcb_screw_holes) {
         diameter_outer = 6.25;
 
         difference() {
-            cylinder(h, d=diameter_inner);
             cylinder(h, d=diameter_outer);
+
+            translate([0, 0, -eps])
+            cylinder(h + 2*eps, d=diameter_inner);
+        }
+    }
+
+    module screw_posts() {
+        posts = [
+            /* Upper row */
+            [screw_post_x_offset,   screw_post_upper_y_offset, screw_post_corner_height],
+            [case_width_bottom / 2, screw_post_upper_y_offset, screw_post_middle_height],
+            [case_width_bottom - screw_post_x_offset, screw_post_upper_y_offset, screw_post_corner_height],
+
+            /* Middle row */
+            [screw_post_x_offset, screw_post_middle_y_offset, screw_post_corner_height],
+            [case_width_bottom - screw_post_x_offset, screw_post_middle_y_offset, screw_post_corner_height],
+
+            /* Bottom row */
+            [screw_post_x_offset, screw_post_lower_y_offset, screw_post_corner_height],
+            [case_width_bottom / 2, screw_post_lower_y_offset, screw_post_corner_height],
+            [case_width_bottom - screw_post_x_offset, screw_post_lower_y_offset, screw_post_corner_height]
+        ];
+
+        for (post = posts) {
+            translate([post[0], post[1], wall_height - wall_width - post[2]])
+            screw_post(post[2]);
         }
     }
 
@@ -88,14 +117,14 @@ module top_case(key_switch_sizes, pcb_screw_holes) {
         height = dimensions[1];
 
         module right_triangle(base) {
-            hypot = sqrt(2 * (base ^ 2 ));
+            hypot = sqrt(2*(base^2));
 
-            difference() {
-                square([base, base], false);
+            intersection() {
+                square([base, base]);
 
-                translate([base, 0, 0])
-                rotate([0, 0, 45])
-                square([hypot, hypot], false);
+                translate([-base, 0, 0])
+                rotate([0, 0, -45])
+                square([hypot, hypot]);
             }
         }
 
@@ -188,7 +217,7 @@ module top_case(key_switch_sizes, pcb_screw_holes) {
                        support_y_offset + y - wall_width + support_width,
                        wall_height - wall_width])
             rotate([0, 0, -90])
-            support([left_support_length + 0.0001, keyboard_switch_height], support_width);
+            support([left_support_length, keyboard_switch_height], support_width);
         }
     }
 
@@ -215,8 +244,8 @@ module top_case(key_switch_sizes, pcb_screw_holes) {
         pcb_screw_diameter = 2.5;
 
         for (screw_hole = pcb_screw_holes) {
-            translate([screw_hole[0], screw_hole[1], 0])
-            cylinder(h=wall_width, d=pcb_screw_diameter);
+            translate([screw_hole[0], screw_hole[1], -eps])
+            cylinder(h=wall_width+2*eps, d=pcb_screw_diameter);
         }
     }
 
@@ -242,12 +271,11 @@ module top_case(key_switch_sizes, pcb_screw_holes) {
                 hole_x = plate_width  / 2 - hole_width  / 2;
                 hole_y = plate_length / 2 - hole_length / 2;
 
-                linear_extrude(wall_width)
                 difference() {
-                    square([plate_width, plate_length], false);
+                    cube([plate_width, plate_length, wall_width], false);
 
-                    translate([hole_x, hole_y, 0])
-                    square([hole_width, hole_length], false);
+                    translate([hole_x, hole_y, -eps])
+                    cube([hole_width, hole_length, wall_width + 2*eps], false);
                 }
             }
         }
@@ -307,6 +335,7 @@ module top_case(key_switch_sizes, pcb_screw_holes) {
     }
 
     supports();
+    screw_posts();
 
     translate([keyboard_x_offset, keyboard_y_offset, keyboard_deck_z_offset])
     keyboard_deck();