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

* Battery holder
* Power cable cutoff
* Dimensional fixes

notebook_nueva/cpu_holder.py

@@ -0,0 +1,28 @@
+import cadquery2 as cq
+from cadquery2 import exporters
+
+lower_stands = (
+    cq.Sketch().push([(0, 0), (58, 0), (58, 23), (0, 23)]).circle(3, mode="a")
+)
+
+higher_stands = (
+    cq.Sketch().push([(0, 0), (58, 0), (58, 23), (0, 23)]).circle(2.65 / 2, mode="a")
+)
+
+model = (
+    cq.Workplane("XY")
+    .workplane()
+    .box(75, 40, 2)
+    .edges("+Z")
+    .fillet(3)
+    .faces(">Z")
+    .workplane(centerOption="CenterOfBoundBox")
+    .center(-29, -11.5)
+    .placeSketch(lower_stands)
+    .extrude(4)
+    .workplane()
+    .placeSketch(higher_stands)
+    .extrude(9)
+)
+
+exporters.export(model, "cpu_holder.stl")

notebook_nueva/modelo.py

@@ -4,22 +4,26 @@ from cadquery2 import exporters
 # Base for the notebook. Basically a kbd base that extends back
 # as much as possible
 
-# Size of the whole object
-width = 295
-height = 165
-thickness = 25
-
-kbd_height = 100
-kbd_angle = 6
-
 # Thickness of the outer material
 shell_t = 3
 
+# Size of the kbd board
+kbd_height = 98
+kbd_width = 286
+kbd_angle = 5
+
+# Size of the whole object
+width = kbd_width + 2 * shell_t
+height = 164  # Max bed size
+thickness = 20 + shell_t  # 20 inside
+
 # Insert Positions
 ti_radius = 2.35
 ti_depth = 6.25
 
-pillars = (
+# Positions are determined by measuring the keyboard
+# mounting holes
+kbd_pillars = (
     cq.Sketch()
     .push(
         [
@@ -31,10 +35,58 @@ pillars = (
             (261.5, -86),
         ]
     )
-    .trapezoid(12, 12, 90, mode="a")
+    .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
+# parts of the case.
+# Measured from top-left corner OUTSIDE
+mounting_pillar_positions = [
+    (6, -6),
+    (width - 6, -6),
+    (width - 6, -40),
+    (120, -6),
+    (170, -6),
+]
+
+mounting_pillars = (
+    cq.Sketch()
+    .push(mounting_pillar_positions)
+    .trapezoid(12, 12, 90, mode="a")
+    .circle(1.8, mode="s")
+)
+
+screw_holes = cq.Sketch().push(mounting_pillar_positions).circle(3, mode="a")
+
+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():
     return (
@@ -47,13 +99,37 @@ 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")
+        .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")
-        .center(-width / 2, 17)
+        # 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))
         .tag("sloped")
-        .placeSketch(pillars)
+        .placeSketch(kbd_pillars)
         .extrude(-1000)
         # Remove the excess extrusion
         .workplaneFromTagged("mid_height")
@@ -62,41 +138,63 @@ def model():
         # Slope for the beyboard
         .workplaneFromTagged("sloped")
         .split(keepBottom=True)
+        # Pillars to join with top half
+        .workplaneFromTagged("mid_height")
+        .workplane(offset=-thickness / 2, centerOption="CenterOfBoundBox")
+        .center(-width / 2, height / 2)
+        .placeSketch(mounting_pillars)
+        .extrude(thickness)
+        # Holes to insert screws from the bottom
+        .workplaneFromTagged("mid_height")
+        .workplane(offset=-thickness / 2, centerOption="CenterOfBoundBox")
+        .center(-width / 2, height / 2)
+        .placeSketch(screw_holes)
+        # 13 is 20-7 (screw thread length - threaded insert depth)
+        .cutBlind(thickness - 13)
     )
 
-top_right = (
-    model()
-    .faces(">Y")
-    .workplane(offset = -120).split(keepTop=True)
-    .faces(">X")
-    .workplane(offset=-135).split(keepTop=True)
-)
-exporters.export(top_right, "top_right.stl")
 
-top_left = (
-    model()
-    .faces(">Y")
-    .workplane(offset = -120).split(keepTop=True)
-    .faces(">X")
-    .workplane(offset=-135).split(keepBottom=True)
-)
-exporters.export(top_left, "top_left.stl")
+if __name__ == "__main__":
 
-bottom_right = (
-    model()
-    .faces(">Y")
-    .workplane(offset = -120).split(keepBottom=True)
-    .faces(">X")
-    .workplane(offset=-165).split(keepTop=True)
-)
-exporters.export(bottom_right, "bottom_right.stl")
+    left_cutout = cq.Sketch().polygon(
+        [(0, 0), (160, 0), (160, -100), (135, -100), (135, -200), (0, -200), (0, 0)],
+        mode="a",
+    )
 
-bottom_left = (
-    model()
-    .faces(">Y")
-    .workplane(offset = -120).split(keepBottom=True)
-    .faces(">X")
-    .workplane(offset=-165).split(keepBottom=True)
-)
-exporters.export(bottom_left, "bottom_left.stl")
+    right_side = (
+        model()
+        .faces("<Z")
+        .workplaneFromTagged("mid_height")
+        .transformed(offset=cq.Vector(0, 0, -thickness / 2))
+        .center(-width / 2, height / 2)
+        .placeSketch(left_cutout)
+        .cutBlind(100)
+    )
 
+    exporters.export(right_side, "right_side.stl")
+
+    right_cutout = cq.Sketch().polygon(
+        [
+            (160, 0),
+            (width, 0),
+            (width, -height),
+            (135, -height),
+            (135, -100),
+            (160, -100),
+            (160, 0),
+        ],
+        mode="a",
+    )
+
+    left_side = (
+        model()
+        .faces("<Z")
+        .workplaneFromTagged("mid_height")
+        .transformed(offset=cq.Vector(0, 0, -thickness / 2))
+        .center(-width / 2, height / 2)
+        .placeSketch(right_cutout)
+        .cutBlind(100)
+    )
+    exporters.export(left_side, "left_side.stl")
+
+    exporters.export(model(), "model.stl")

notebook_nueva/screen_mount.py

@@ -0,0 +1,133 @@
+import cadquery2 as cq
+from cadquery2 import exporters
+
+from modelo import (
+    kbd_height,
+    kbd_width,
+    mounting_pillar_positions,
+    shell_t,
+    ti_depth,
+    ti_radius,
+)
+
+ti_radius = 2.5
+
+# Size of the whole object
+width = kbd_width + 2 * shell_t
+height = 59
+thickness = 62  # Will be shorter after construction
+
+# Visible screen size
+vis_w = 220
+vis_h = 58
+viewport_cutout = cq.Sketch().trapezoid(vis_w, vis_h, 90, mode="a")
+
+# Whole screen size
+scr_w = 231
+scr_h = 65
+scr_thickness = 5.5
+screen_cutout = cq.Sketch().trapezoid(scr_w, scr_h, 90, mode="a")
+
+# 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.
+board_cutout = cq.Sketch().trapezoid(
+    scr_w + 5,
+    scr_h - 10,
+    90,
+    mode="a",
+)
+
+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)
+    .circle(ti_radius, mode="s")
+)
+
+
+def model():
+    return (
+        cq.Workplane("XY")
+        .workplane()
+        .tag("mid_height")
+        .box(width, height, thickness)
+        # The screen goes at a 45 degree angle
+        .faces(">Z")
+        .transformed(rotate=(45, 0, 0))
+        # Move the screen "lower" so it doesn't interfere
+        # so much with the back
+        .center(0, -2)
+        .tag("slanted")
+        # Arbitrary huge trapezoid to cut off the material *in front*
+        # of the inclined screen
+        .placeSketch(cq.Sketch().trapezoid(1000, 1000, 90, mode="a"))
+        .cutBlind(1000)
+        # Cut off viewport hole so we can see the screen
+        .workplaneFromTagged("slanted")
+        .placeSketch(viewport_cutout)
+        .cutBlind(-shell_t)
+        # Make hole for screen assembly so the whole screen fits
+        .workplaneFromTagged("slanted")
+        .workplane(offset=-shell_t, centerOption="CenterOfBoundBox")
+        # Left bezel is wider than right one, so this hole is displaced to the left
+        .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
+        .shell(-shell_t + 0.01)
+        # Cut hole for the screen board and cables
+        .workplaneFromTagged("slanted")
+        .workplane(offset=-scr_thickness, centerOption="CenterOfBoundBox")
+        .placeSketch(board_cutout)
+        .cutBlind(-6)
+        # 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 / 2)
+        .placeSketch(mounting_pillars)
+        .extrude(10)
+    )
+
+
+exporters.export(model(), "screen_mount.stl")
+
+split_offset = -133
+
+right_side = (
+    model()
+    .faces(">X")
+    .workplane(centerOption="CenterOfBoundBox", offset=split_offset)
+    .center(0, height / 2)
+    .split(keepTop=True)
+)
+
+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)
+)
+
+exporters.export(left_side, "left_screen_mount.stl")