Large design change.

While not as pretty this should work much better mechanically
based on the results from the last test print.

* Added room for the plugs to slide from the middle outwards
* Made back reinforcement much larger so it connects the piece that is
  split by that plug channel
* Removed separate board cutout (not needed anymore)
* Fix cable channel (was cutting through end caps)
* Change shelling parameters so it keeps a cap on both ends
* Adjusted segment breaks for new reality

* TODO: adjust rear hinge design to be flat and not "envolving"

monitor/case.py

@@ -11,14 +11,15 @@ board_cutout = (
     cq.Sketch().trapezoid(55, 50, 90, mode="a").reset().vertices("<X").fillet(5)
 )
 
-plug_cutout = cq.Sketch().trapezoid(55, 11, 90, mode="a").reset().vertices("<X")
+plug_channel_cutout = cq.Sketch().trapezoid(45, 6, 90, mode="a").reset().vertices("<X")
 
-cable_relief = cq.Sketch().trapezoid(width, 30, 90)
+cable_relief = cq.Sketch().trapezoid(width - 2 * shell_t, 30, 90)
 
+break_depth = 20
 segment_breaks_top = (
     cq.Sketch()
     .rarray(1, length, 1, 1)
-    .trapezoid(width / 3, 35, 110, mode="a")
+    .trapezoid(width / 3, break_depth, 110, mode="a")
     .reset()
     .vertices()
     .fillet(5)
@@ -27,14 +28,14 @@ segment_breaks_top = (
 segment_breaks_bottom = (
     cq.Sketch()
     .rarray(1, length, 1, 1)
-    .trapezoid(width / 3, 35, 70, mode="a")
+    .trapezoid(width / 3, break_depth, 70, mode="a")
     .reset()
     .vertices()
     .fillet(5)
 )
 
 back_reinforcement = (
-    cq.Sketch().trapezoid(width / 2, 15, 90, mode="a").reset().vertices().fillet(2)
+    cq.Sketch().trapezoid(width / 2, length-break_depth, 90, mode="a").reset().vertices().fillet(2)
 )
 
 threaded_inserts = cq.Sketch().rarray(width / 8, 0, 4, 1).circle(ti_radius, mode="a")
@@ -50,16 +51,9 @@ def case():
         .lineTo(0, height)
         .close()
         .extrude(length)
-        .faces(">X")
         .shell(-shell_t)
         .edges("|X")
         .fillet(fillet_s)
-        # Cutout room for plugs to slide in and be exposed
-        .faces(">X")
-        .workplane(centerOption="CenterOfBoundBox")
-        .center(0, -5)
-        .placeSketch(plug_cutout)
-        .cutBlind(-width / 2)
         # Cutout visible screen area from top face
         .faces(">Z")
         .workplane(centerOption="CenterOfBoundBox")
@@ -75,12 +69,6 @@ def case():
         .center(0, -length)
         .placeSketch(segment_breaks_bottom)
         .cutBlind(-1000)
-        # Cutout for the circuit board
-        .faces("<Z")
-        .workplane(centerOption="CenterOfBoundBox")
-        .center(width / 2 - 27.5, 0)
-        .placeSketch(board_cutout)
-        .cutBlind(-shell_t)
         # Make some room for the ribbon cable
         .faces("<Z[-2]")
         .workplane(centerOption="CenterOfBoundBox")
@@ -90,11 +78,17 @@ def case():
         .faces("<Z")
         .workplane(centerOption="CenterOfBoundBox")
         .placeSketch(back_reinforcement)
-        .extrude(1 + 1 + ti_depth - shell_t)
+        .extrude(7 + ti_depth - shell_t)
         .faces("<Z")
         .workplane(centerOption="CenterOfBoundBox")
         .placeSketch(threaded_inserts)
         .cutBlind(-ti_depth)
+        # Cutout room for plugs to slide in and be exposed
+        .faces(">X")
+        .workplane(centerOption="CenterOfBoundBox")
+        .center(0, -5)
+        .placeSketch(plug_channel_cutout)
+        .cutBlind(-width / 2)
     )
 
 

monitor/parameters.py

@@ -9,6 +9,7 @@ screen_left_margin = 7 + shell_t  #  (7 is bezel width on that side)
 # width, length, height INCLUDING_BEZEL
 display_w = 233
 display_l = 65
+# This is the general height without the board, that's handled separately
 display_h = 5
 
 width = 250