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

notebook_nueva/modelo.py

@@ -21,7 +21,9 @@ thickness = 20 + shell_t  # 20 inside
 ti_radius = 2.35
 ti_depth = 6.25
 
-pillars = (
+# Positions are determined by measuring the keyboard
+# mounting holes
+kbd_pillars = (
     cq.Sketch()
     .push(
         [
@@ -34,9 +36,30 @@ pillars = (
         ]
     )
     .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(
@@ -49,6 +72,11 @@ battery_holder = (
         [(-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",
+    )
 )
 
 
@@ -57,6 +85,9 @@ 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 (
         cq.Workplane("XY")
@@ -88,7 +119,7 @@ def model():
         # Hole for power switch
         .faces(">Y")
         .workplane(centerOption="CenterOfBoundBox")
-        .center(-height / 2 + shell_t + 50, 0)
+        .center(0, 0)
         .placeSketch(switch_in)
         .cutBlind(-shell_t)
         # Slanted mounting pillars on the kbd top
@@ -98,7 +129,7 @@ def model():
         .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")
@@ -107,15 +138,30 @@ 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)
     )
 
 
-left_cutout = cq.Sketch().polygon(
+if __name__ == "__main__":
+
+    left_cutout = cq.Sketch().polygon(
         [(0, 0), (160, 0), (160, -100), (135, -100), (135, -200), (0, -200), (0, 0)],
         mode="a",
-)
+    )
 
-right_side = (
+    right_side = (
         model()
         .faces("<Z")
         .workplaneFromTagged("mid_height")
@@ -123,11 +169,11 @@ right_side = (
         .center(-width / 2, height / 2)
         .placeSketch(left_cutout)
         .cutBlind(100)
-)
+    )
 
-exporters.export(right_side, "right_side.stl")
+    exporters.export(right_side, "right_side.stl")
 
-right_cutout = cq.Sketch().polygon(
+    right_cutout = cq.Sketch().polygon(
         [
             (160, 0),
             (width, 0),
@@ -138,9 +184,9 @@ right_cutout = cq.Sketch().polygon(
             (160, 0),
         ],
         mode="a",
-)
+    )
 
-left_side = (
+    left_side = (
         model()
         .faces("<Z")
         .workplaneFromTagged("mid_height")
@@ -148,7 +194,7 @@ left_side = (
         .center(-width / 2, height / 2)
         .placeSketch(right_cutout)
         .cutBlind(100)
-)
-exporters.export(left_side, "left_side.stl")
+    )
+    exporters.export(left_side, "left_side.stl")
 
-exporters.export(model(), "model.stl")
+    exporters.export(model(), "model.stl")

notebook_nueva/screen_mount.py

@@ -1,21 +1,21 @@
 import cadquery2 as cq
 from cadquery2 import exporters
 
-# Dimensions copied from modelo.py,
-# TODO refactor into a separate file
+from modelo import (
+    kbd_height,
+    kbd_width,
+    mounting_pillar_positions,
+    shell_t,
+    ti_depth,
+    ti_radius,
+)
 
-# Thickness of the outer material
-shell_t = 3
-
-# Size of the kbd board
-kbd_height = 98
-kbd_width = 286
-kbd_angle = 5
+ti_radius = 2.5
 
 # Size of the whole object
 width = kbd_width + 2 * shell_t
-height = 69
-thickness = 10
+height = 59
+thickness = 62  # Will be shorter after construction
 
 # Visible screen size
 vis_w = 220
@@ -28,26 +28,23 @@ scr_h = 65
 scr_thickness = 5.5
 screen_cutout = cq.Sketch().trapezoid(scr_w, scr_h, 90, mode="a")
 
-# Circuit board and cable space
-board_cutout = cq.Sketch().polygon(
-    [
-        (0, 0),
-        (width / 2 - 10, 0),
-        (width / 2 - 10, vis_h - 20),
-        (0, vis_h - 20),
-        (0, 0),
-    ],
+# 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",
 )
-board_cutout_2 = cq.Sketch().polygon(
-    [
-        (0, 0),
-        (width / 2 - 10 + 4, 0),
-        (width / 2 - 10 + 4, vis_h - 20 + 4),
-        (0, vis_h - 20 + 4),
-        (0, 0),
-    ],
-    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")
 )
 
 
@@ -55,67 +52,82 @@ def model():
     return (
         cq.Workplane("XY")
         .workplane()
-        .box(width, 59, 59)
+        .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
+        # Cut off viewport hole so we can see the screen
         .workplaneFromTagged("slanted")
         .placeSketch(viewport_cutout)
         .cutBlind(-shell_t)
-        # Make hole for screen assembly
+        # Make hole for screen assembly so the whole screen fits
         .workplaneFromTagged("slanted")
         .workplane(offset=-shell_t, centerOption="CenterOfBoundBox")
-        # Left bezel is 4mm wider than right one, so this hole is displaced to the left
-        # Cut for the scren assembly
-        .center(-4, 0)
+        # Left bezel is wider than right one, so this hole is displaced to the left
+        .center(-3, 0)
         .placeSketch(screen_cutout)
         .cutBlind(-scr_thickness)
-        # Cut for the screen board and cables
-        .workplaneFromTagged("slanted")
-        .workplane(offset=-shell_t - scr_thickness, centerOption="CenterOfBoundBox")
-        .center(0, -(vis_h - 20) / 2)
-        .placeSketch(board_cutout)
-        .cutBlind(-5)
+        # 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")
-        .shell(-2)
-        # Cut AGAIN for the screen board and cables
+        # 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=-shell_t - scr_thickness, centerOption="CenterOfBoundBox")
-        .center(0, -(vis_h -20 + 4) / 2)
-        .placeSketch(board_cutout_2)
-        .cutBlind(-7)
+        .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")
 
-left_cutout = cq.Sketch().polygon(
-    [(0, 0), (160, 0), (160, -100), (0, -100), (0, 0)],
-    mode="a",
-)
+split_offset = -133
 
 right_side = (
     model()
-    .faces("<Z")
-    .workplane(centerOption="CenterOfBoundBox", offset=3)
-    .center(-width / 2, height / 2)
-    .placeSketch(left_cutout)
-    .cutBlind(-100)
+    .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("<Z")
-    .workplane(centerOption="CenterOfBoundBox", offset=3)
+    .faces(">X")
+    .workplane(centerOption="CenterOfBoundBox", offset=split_offset)
     .center(0, height / 2)
-    .placeSketch(left_cutout)
-    .cutBlind(-100)
+    .split(keepBottom=True)
 )
 
 exporters.export(left_side, "left_screen_mount.stl")