Fit into resin printer volume, make holes larger because resin doesn't melt

notebook_nueva/modelo.py

@@ -8,13 +8,13 @@ from cadquery2 import exporters
 shell_t = 3
 
 # Size of the kbd board
-kbd_height = 95.5
-kbd_width = 305
+kbd_height = 98
+kbd_width = 286
 kbd_angle = 5
 
 # Size of the whole object
 width = kbd_width + 2 * shell_t
-height = 159
+height = 164  # Max bed size
 thickness = 20 + shell_t  # 20 inside
 
 # Insert Positions
@@ -22,34 +22,22 @@ ti_radius = 2.35
 ti_depth = 6.25
 
 # Positions are determined by measuring the keyboard
-
-kbd_pillar_positions = [
-    (18.25, -16),
-    (142.5, -25.5),
-    (kbd_width - 20, -16),
-    (23.5, -79.5),
-    (145.5, -82.5),
-    (kbd_width - 19, -79.5),
-]
-
-
-# 2-level mounting pillars for the kbd
-# Width of these need to be tweaked for
-# each specific keyboard
+# mounting holes
 kbd_pillars = (
     cq.Sketch()
-    .push(kbd_pillar_positions)
-    .circle(2.2, mode="a")
-    # Holes for self-tapping screws
-    .circle(1.1, mode="s")
-)
-
-kbd_lower_pillars = (
-    cq.Sketch()
-    .push(kbd_pillar_positions)
-    .circle(4, mode="a")
-    # Holes for self-tapping screws
-    .circle(1.1, mode="s")
+    .push(
+        [
+            (19, -16.5),
+            (133, -16.5),
+            (247.5, -16.5),
+            (24, -86),
+            (142.5, -91),
+            (261.5, -86),
+        ]
+    )
+    .circle(6, mode="a")
+    # Holes for M3 threaded inserts
+    .circle(ti_radius, mode="s")
 )
 
 # These are placed where convenient, and are used to join the top and bottom
@@ -57,11 +45,10 @@ kbd_lower_pillars = (
 # Measured from top-left corner OUTSIDE
 mounting_pillar_positions = [
     (6, -6),
-    (6, -40),
-    (120, -6),
-    (170, -6),
     (width - 6, -6),
     (width - 6, -40),
+    (120, -6),
+    (170, -6),
 ]
 
 mounting_pillars = (
@@ -73,8 +60,32 @@ mounting_pillars = (
 
 screw_holes = cq.Sketch().push(mounting_pillar_positions).circle(3, mode="a")
 
-# Hole for the USB hub's exposed port
+battery_holder = (
+    cq.Sketch()
+    .polygon(
+        [(-67, 5), (0, 5), (0, -12), (-67, -12), (-67, 5)],
+        mode="a",
+    )
+    .trapezoid(83, 83, 90, mode="a")
+    .trapezoid(80, 80, 90, mode="s")
+    .polygon(
+        [(-67, 3), (0, 3), (0, -10), (-67, -10), (-67, 3)],
+        mode="s",
+    )
+    # Cutout for the
+    .polygon(
+        [(-67, 30), (0, 30), (0, 12), (-67, 12), (-67, 30)],
+        mode="s",
+    )
+)
+
+
+power_in = cq.Sketch().circle(5, mode="a")
 usb_in = cq.Sketch().trapezoid(13, 5.5, 90, mode="a")
+switch_in = cq.Sketch().trapezoid(13.5, 8, 90, mode="a")
+
+
+# Motherboard mount
 
 
 def model():
@@ -88,30 +99,38 @@ def model():
         .fillet(2)
         .faces(">Z")
         .shell(-shell_t)
+        # Battery holder
+        .workplaneFromTagged("mid_height")
+        .center(-width / 2 + shell_t + 65, height / 2 - shell_t - 45)
+        .placeSketch(battery_holder)
+        .extrude(-height / 2)
+        # Power cable inlet
+        .faces("<X")
+        .workplane(centerOption="CenterOfBoundBox")
+        .center(-height / 2 + shell_t + 48.5, -3)
+        .placeSketch(power_in)
+        .cutBlind(-shell_t)
         # USB inlet
         .faces(">X")
         .workplane(centerOption="CenterOfBoundBox")
-        # The position is arbitrary, based on the components 
-        # available, keyboard height, cable length, etc.
-        .center(-height / 2 + shell_t + 60, -5)
+        .center(-height / 2 + shell_t + 50, -5)
         .placeSketch(usb_in)
         .cutBlind(-shell_t)
+        # Hole for power switch
+        .faces(">Y")
+        .workplane(centerOption="CenterOfBoundBox")
+        .center(0, 0)
+        .placeSketch(switch_in)
+        .cutBlind(-shell_t)
         # Slanted mounting pillars on the kbd top
         .faces(">Z")
         .workplane(centerOption="CenterOfBoundBox")
         # Top-left kbd corner inside the box
         .center(-width / 2 + shell_t, kbd_height - height / 2 + shell_t)
         .transformed(rotate=cq.Vector(kbd_angle, 0, 0))
-        # These two offsets push the keyboard "down" into the case
-        # and need to be adjusted per-keyboard
         .tag("sloped")
-        .workplane(offset=-2.5)
         .placeSketch(kbd_pillars)
         .extrude(-1000)
-        .workplaneFromTagged("sloped")
-        .workplane(offset=-5.5)
-        .placeSketch(kbd_lower_pillars)
-        .extrude(-1000)
         # Remove the excess extrusion
         .workplaneFromTagged("mid_height")
         .transformed(offset=cq.Vector(0, 0, -thickness / 2))
@@ -138,7 +157,7 @@ def model():
 if __name__ == "__main__":
 
     left_cutout = cq.Sketch().polygon(
-        [(0, 0), (width / 2, 0), (width / 2, -height), (0, -height), (0, 0)],
+        [(0, 0), (160, 0), (160, -100), (135, -100), (135, -200), (0, -200), (0, 0)],
         mode="a",
     )
 
@@ -156,11 +175,13 @@ if __name__ == "__main__":
 
     right_cutout = cq.Sketch().polygon(
         [
-            (width / 2, 0),
+            (160, 0),
             (width, 0),
             (width, -height),
-            (width / 2, -height),
-            (width / 2, 0),
+            (135, -height),
+            (135, -100),
+            (160, -100),
+            (160, 0),
         ],
         mode="a",
     )

notebook_nueva/screen_mount.py

@@ -10,11 +10,12 @@ from modelo import (
     ti_radius,
 )
 
+ti_radius = 2.5
+
 # Size of the whole object
 width = kbd_width + 2 * shell_t
-height = 66
-height_bottom = 59
-thickness = 48  # Will be shorter after construction
+height = 59
+thickness = 62  # Will be shorter after construction
 
 # Visible screen size
 vis_w = 220
@@ -27,9 +28,6 @@ scr_h = 65
 scr_thickness = 5.5
 screen_cutout = cq.Sketch().trapezoid(scr_w, scr_h, 90, mode="a")
 
-# Screen angle
-scr_angle = 20
-
 # Circuit board and cable hole.
 # This is in the back of the screen, and is a bit shorter in height than the
 # screen. It's wider so it removes enough material to make the shape simpler.
@@ -40,15 +38,13 @@ board_cutout = cq.Sketch().trapezoid(
     mode="a",
 )
 
-kbd_cable_hole = cq.Sketch().trapezoid(20, 9, 90, mode="a").vertices().fillet(1)
+kbd_cable_hole = cq.Sketch().trapezoid(15, 5, 90, mode="a").vertices().fillet(1)
 
 mounting_pillars = (
     cq.Sketch()
     .polygon([(0, 0), (width, 0), (width, -12), (0, -12), (0, 0)], mode="a")
     .push(mounting_pillar_positions)
-    .trapezoid(-12, 12, 90, mode="a")
     .circle(ti_radius, mode="s")
-    .clean()
 )
 
 
@@ -58,9 +54,9 @@ def model():
         .workplane()
         .tag("mid_height")
         .box(width, height, thickness)
-        # The screen goes rotated
+        # The screen goes at a 45 degree angle
         .faces(">Z")
-        .transformed(rotate=(scr_angle, 0, 0))
+        .transformed(rotate=(45, 0, 0))
         # Move the screen "lower" so it doesn't interfere
         # so much with the back
         .center(0, -2)
@@ -69,35 +65,6 @@ def model():
         # of the inclined screen
         .placeSketch(cq.Sketch().trapezoid(1000, 1000, 90, mode="a"))
         .cutBlind(1000)
-        # Trim the top
-        .workplaneFromTagged("mid_height")
-        .workplane(offset=21)
-        .placeSketch(cq.Sketch().trapezoid(1000, 1000, 90, mode="a"))
-        .cutBlind(100)
-        # Make bottom smaller to fit with base
-        .faces(">X")
-        .workplane(centerOption="CenterOfBoundBox")
-        .center(-height / 2, -thickness / 2)
-        .placeSketch(
-            cq.Sketch()
-            .polygon(
-                [
-                    (height_bottom, 0),
-                    (height_bottom, thickness / 3),
-                    (height, thickness - 21),
-                    (height, thickness),
-                    (height + 5, thickness + 5),
-                    (height + 5, 0),
-                    (height_bottom, 0),
-                ]
-            )
-            .vertices()
-            .fillet(3)
-        )
-        .cutBlind(-1000)
-        # Fillet top of the object
-        .edges("|X and >Z")
-        .fillet(3)
         # Cut off viewport hole so we can see the screen
         .workplaneFromTagged("slanted")
         .placeSketch(viewport_cutout)
@@ -109,6 +76,11 @@ def model():
         .center(-3, 0)
         .placeSketch(screen_cutout)
         .cutBlind(-scr_thickness)
+        # Trim the top
+        .workplaneFromTagged("mid_height")
+        .workplane(offset=21)
+        .placeSketch(cq.Sketch().trapezoid(1000, 1000, 90, mode="a"))
+        .cutBlind(100)
         # Make it hollow
         .faces("<Z")
         # Can't be exactly shell_t because cq fails
@@ -118,43 +90,44 @@ def model():
         .workplane(offset=-scr_thickness, centerOption="CenterOfBoundBox")
         .placeSketch(board_cutout)
         .cutBlind(-6)
-        # # Make small hole for the keyboard cable
-        # # not needed with this keyboard
-        # .faces("<Y")
-        # .workplane(centerOption="CenterOfBoundBox")
-        # .center(width / 2 - 175, -4)
-        # .placeSketch(kbd_cable_hole)
-        # .cutBlind(-height / 2)
+        # Fillet top of the object
+        .edges(">Z and |X")
+        .fillet(5)
+        # Make small hole for the keyboard cable
+        .faces(">Y")
+        .workplane(offset=-5, centerOption="CenterOfBoundBox")
+        .center(-width / 2 + 128, -23)
+        .placeSketch(kbd_cable_hole)
+        .cutBlind(-1000)
         # Pillars to join with bottom half
         .workplaneFromTagged("mid_height")
         .workplane(offset=-thickness / 2, centerOption="CenterOfBoundBox")
-        .center(-width / 2, height_bottom - height / 2)
+        .center(-width / 2, height / 2)
         .placeSketch(mounting_pillars)
         .extrude(10)
     )
 
 
-if __name__ == "__main__":
+exporters.export(model(), "screen_mount.stl")
 
-    print("Exporting")
-    exporters.export(model(), "screen_mount.stl")
+split_offset = -133
 
-    offset_width = -width / 2
+right_side = (
+    model()
+    .faces(">X")
+    .workplane(centerOption="CenterOfBoundBox", offset=split_offset)
+    .center(0, height / 2)
+    .split(keepTop=True)
+)
 
-    right_side = (
-        model()
-        .faces(">X")
-        .workplane(centerOption="CenterOfBoundBox", offset=offset_width)
-        .split(keepTop=True)
-    )
+exporters.export(right_side, "right_screen_mount.stl")
 
-    exporters.export(right_side, "right_screen_mount.stl")
+left_side = (
+    model()
+    .faces(">X")
+    .workplane(centerOption="CenterOfBoundBox", offset=split_offset)
+    .center(0, height / 2)
+    .split(keepBottom=True)
+)
 
-    left_side = (
-        model()
-        .faces(">X")
-        .workplane(centerOption="CenterOfBoundBox", offset=offset_width)
-        .split(keepBottom=True)
-    )
-
-    exporters.export(left_side, "left_screen_mount.stl")
+exporters.export(left_side, "left_screen_mount.stl")