comment

This cut is not needed with the lower keyboard position.

notebook_nueva/audio_plug.py

@@ -0,0 +1,16 @@
+# Hole to expose a USB audio card (YMMV)
+
+# The hole is for a USB-A plug, y is measured in the hub
+# (from the bottom face to middle of the hole)
+# Consumers should set proper offsets for the hole
+
+holes = [
+    # 2-jack plug
+    {
+        "x": 0,
+        "y": 4,
+        "height": 6,
+        "width": 17,
+        "fillet": 2,
+    },
+]

notebook_nueva/battery_holder.py

@@ -0,0 +1,73 @@
+import cadquery as cq
+
+stand_positions = [(0, 0), (58, 0), (58, 49), (0, 49)]
+stands = (
+    cq.Sketch().push(stand_positions).circle(3, mode="a").circle(2.65 / 2, mode="s")
+)
+pillar_height = 7
+
+
+# This is a holder for DuPont cables so they connect to this
+# things' pogo pins which are used to power the CPU
+pin_positions = [(3.5, 0), (4 * 2.54 + 3.5, 0)]
+pin_holder_width = 25
+pin_holder_height = 15
+pin_holder = (
+    cq.Sketch()
+    .polygon(
+        [
+            (0.5, 0),
+            (pin_holder_width, 0),
+            (pin_holder_width, pin_holder_height),
+            (0, pin_holder_height),
+            (0.5, 0),
+        ],
+        mode="a",
+    )
+    .push(pin_positions)
+    .polygon(
+        [(0, 0), (2.6, 0), (2.6, pin_holder_height), (0, pin_holder_height), (0, 0)],
+        mode="s",
+    )
+)
+
+elements = [
+    # Battery holder stands
+    {
+        "x": 0,
+        "y": 0,
+        "shape": stands,
+        "height": pillar_height,
+    },
+    # Pogo pin connector channels
+    {
+        "x": 0,
+        "y": 40,
+        "shape": pin_holder,
+        "height": 3,
+    },
+]
+
+
+# Hole distances are relative to the rightmost pillar
+# seen from the back of the case, that's why they are negative
+# Heights are relative to base of pillars
+# All distances are measured to the CENTER of the hole
+holes = [
+    # Power inlet
+    {
+        "x": -15,
+        "y": -1 + pillar_height,
+        "height": 6.5,
+        "width": 12,
+        "fillet": 1,
+    },
+    # Power button
+    {
+        "x": -67,
+        "y": 5.5 + pillar_height,
+        "height": 7,
+        "width": 7,
+        "fillet": 1,
+    },
+]

notebook_nueva/cpu_holder.py

@@ -1,28 +0,0 @@
-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

@@ -1,5 +1,11 @@
-import cadquery2 as cq
-from cadquery2 import exporters
+import cadquery as cq
+from cadquery import exporters
+
+import audio_plug
+import battery_holder
+import usb_hub
+import zero_holder as cpu_holder
+from utils import extrude_shape, punch_hole
 
 # Base for the notebook. Basically a kbd base that extends back
 # as much as possible
@@ -8,36 +14,48 @@ from cadquery2 import exporters
 shell_t = 3
 
 # Size of the kbd board
-kbd_height = 98
-kbd_width = 286
+kbd_height = 95.5
+kbd_width = 305
 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
+height = 159
+thickness = 27 + shell_t  # 27 inside
 
 # Insert Positions
 ti_radius = 2.35
 ti_depth = 6.25
 
 # Positions are determined by measuring the keyboard
-# mounting holes
+
+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
 kbd_pillars = (
     cq.Sketch()
-    .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")
+    .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")
 )
 
 # These are placed where convenient, and are used to join the top and bottom
@@ -45,10 +63,11 @@ kbd_pillars = (
 # Measured from top-left corner OUTSIDE
 mounting_pillar_positions = [
     (6, -6),
-    (width - 6, -6),
-    (width - 6, -40),
+    (6, -40),
     (120, -6),
     (170, -6),
+    (width - 6, -6),
+    (width - 6, -30),
 ]
 
 mounting_pillars = (
@@ -60,36 +79,30 @@ mounting_pillars = (
 
 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",
-    )
-)
+# Thing to "grab" the hub so it stays in place
+# Distance from edge to center of USB plug
+usb_offset = 48
 
 
-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")
+# CPU holder position from back-left corner of the case
+cpu_offset_x = 160
+cpu_offset_y = 25
 
+# Battery holder position from back-left corner of the case
+battery_offset_x = 22
+battery_offset_y = 8
 
-# Motherboard mount
+# Offset for the USB port from back-right corner of the case
+usb_offset = 48
 
 
 def model():
-    return (
+    # Create the basic shape of the case bottom.
+
+    # Currently also adds keyboard stuff and things to connect
+    # to the screen case, but that should be refactored
+    # out (FIXME)
+    model = (
         cq.Workplane("XY")
         .workplane(offset=thickness / 2)
         .tag("mid_height")
@@ -99,38 +112,22 @@ 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")
         # 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))
@@ -153,11 +150,94 @@ def model():
         .cutBlind(thickness - 13)
     )
 
+    # Now the basic box shape is in place, start adding things
+    # and cutting holes.
+
+    # Holes in the back of the case for battery holder
+    for hole in battery_holder.holes:
+        model = punch_hole(
+            model=model,
+            face=">Y",
+            w=width,
+            h=thickness,
+            x_offset=width - battery_offset_x,
+            y_offset=shell_t,
+            hole=hole,
+            depth=shell_t,
+        )
+
+    # Hole for USB hub in the back
+    for hole in usb_hub.holes:
+        model = punch_hole(
+            model=model,
+            face=">Y",
+            w=width,
+            h=thickness,
+            x_offset=usb_offset + shell_t + usb_hub.holes[0]["width"] / 2,
+            y_offset=shell_t,
+            hole=hole,
+            depth=shell_t,
+        )
+
+    # USB hub holder
+    for element in usb_hub.elements:
+        model = extrude_shape(
+            model=model,
+            face="<Z",
+            w=width,
+            h=height,
+            x_offset=width - usb_offset - shell_t - +usb_hub.holes[0]["width"] / 2,
+            y_offset=shell_t + element["y"],
+            shape=element["shape"],
+            height=-(element["height"] + shell_t),
+        )
+
+    # Hole for audio in right side
+    for hole in audio_plug.holes:
+        model = punch_hole(
+            model=model,
+            face=">X",
+            w=height,
+            h=thickness,
+            x_offset=height - shell_t - 34.5 - audio_plug.holes[0]["width"] / 2,
+            y_offset=shell_t,
+            hole=hole,
+            depth=shell_t,
+        )
+
+    # Battery holder stands and pogo pin holder
+    for element in battery_holder.elements:
+        model = extrude_shape(
+            model=model,
+            face="<Z",
+            w=width,
+            h=height,
+            x_offset=battery_offset_x + element["x"],
+            y_offset=shell_t + battery_offset_y + element["y"],
+            shape=element["shape"],
+            height=-(element["height"] + shell_t),
+        )
+
+    # CPU holder stands
+    for element in cpu_holder.elements:
+        model = extrude_shape(
+            model=model,
+            face="<Z",
+            w=width,
+            h=height,
+            x_offset=cpu_offset_x + element["x"],
+            y_offset=shell_t + cpu_offset_y + element["y"],
+            shape=element["shape"],
+            height=-(element["height"] + shell_t),
+        )
+
+    return model
+
 
 if __name__ == "__main__":
 
     left_cutout = cq.Sketch().polygon(
-        [(0, 0), (160, 0), (160, -100), (135, -100), (135, -200), (0, -200), (0, 0)],
+        [(0, 0), (width / 2, 0), (width / 2, -height), (0, -height), (0, 0)],
         mode="a",
     )
 
@@ -175,13 +255,11 @@ if __name__ == "__main__":
 
     right_cutout = cq.Sketch().polygon(
         [
-            (160, 0),
+            (width / 2, 0),
             (width, 0),
             (width, -height),
-            (135, -height),
-            (135, -100),
-            (160, -100),
-            (160, 0),
+            (width / 2, -height),
+            (width / 2, 0),
         ],
         mode="a",
     )

notebook_nueva/screen_mount.py

@@ -1,5 +1,5 @@
-import cadquery2 as cq
-from cadquery2 import exporters
+import cadquery as cq
+from cadquery import exporters
 
 from modelo import (
     kbd_height,
@@ -12,13 +12,14 @@ from modelo import (
 
 # Size of the whole object
 width = kbd_width + 2 * shell_t
-height = 59
-thickness = 62  # Will be shorter after construction
+height = 66
+height_bottom = 59
+thickness = 48  # 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")
+vis_w = 219
+vis_h = 55
+viewport_cutout = cq.Sketch().trapezoid(vis_w, vis_h, 90, mode="a").vertices().fillet(2)
 
 # Whole screen size
 scr_w = 231
@@ -26,6 +27,9 @@ 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.
@@ -36,13 +40,14 @@ board_cutout = cq.Sketch().trapezoid(
     mode="a",
 )
 
-kbd_cable_hole = cq.Sketch().trapezoid(15, 5, 90, mode="a").vertices().fillet(1)
+kbd_cable_hole = cq.Sketch().trapezoid(20, 9, 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()
 )
 
 
@@ -52,9 +57,9 @@ def model():
         .workplane()
         .tag("mid_height")
         .box(width, height, thickness)
-        # The screen goes at a 45 degree angle
+        # The screen goes rotated
         .faces(">Z")
-        .transformed(rotate=(45, 0, 0))
+        .transformed(rotate=(scr_angle, 0, 0))
         # Move the screen "lower" so it doesn't interfere
         # so much with the back
         .center(0, -2)
@@ -63,6 +68,35 @@ 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)
@@ -74,11 +108,6 @@ 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
@@ -88,42 +117,38 @@ def model():
         .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)
+        .center(-width / 2, height_bottom - height / 2)
         .placeSketch(mounting_pillars)
         .extrude(10)
+        # Fillet the front edge of the screen case so it looks softer
+        .edges(">(0, -10, 5)")
+        .fillet(2)
     )
 
 
-exporters.export(model(), "screen_mount.stl")
+if __name__ == "__main__":
 
-right_side = (
-    model()
-    .faces(">X")
-    .workplane(centerOption="CenterOfBoundBox", offset=-width / 2)
-    .center(0, height / 2)
-    .split(keepTop=True)
-)
+    print("Exporting")
+    exporters.export(model(), "screen_mount.stl")
 
-exporters.export(right_side, "right_screen_mount.stl")
+    offset_width = -width / 2
 
-left_side = (
-    model()
-    .faces(">X")
-    .workplane(centerOption="CenterOfBoundBox", offset=-width / 2)
-    .center(0, height / 2)
-    .split(keepBottom=True)
-)
+    right_side = (
+        model()
+        .faces(">X")
+        .workplane(centerOption="CenterOfBoundBox", offset=offset_width)
+        .split(keepTop=True)
+    )
 
-exporters.export(left_side, "left_screen_mount.stl")
+    exporters.export(right_side, "right_screen_mount.stl")
+
+    left_side = (
+        model()
+        .faces(">X")
+        .workplane(centerOption="CenterOfBoundBox", offset=offset_width)
+        .split(keepBottom=True)
+    )
+
+    exporters.export(left_side, "left_screen_mount.stl")

notebook_nueva/usb_hub.py

@@ -0,0 +1,33 @@
+import cadquery as cq
+
+# Measurements for my USB hub, YMMV
+
+# The hole is for a USB-A plug, y is measured in the hub
+# (from the bottom face to middle of the hole)
+# Consumers should set proper offsets for the hole
+
+holes = [
+    # USB-A port
+    {
+        "x": 0,
+        "y": 4,
+        "height": 5.5,
+        "width": 13,
+        "fillet": 2,
+    },
+]
+
+elements = [
+    # Thing to grab the hub
+    {
+        "x": 0,
+        "y": 5,
+        "shape": (
+            cq.Sketch()
+            .trapezoid(22, 10, 90, mode="a")
+            .trapezoid(17, 10, 90, mode="s")
+            .clean()
+        ),
+        "height": 8,
+    }
+]

notebook_nueva/utils.py

@@ -0,0 +1,26 @@
+import cadquery as cq
+
+# TODO make API of extrude_shape and punch_hole more consistent
+def extrude_shape(*, model, face, w, h, x_offset, y_offset, shape, height):
+    return (
+        model.faces(face)
+        .workplane(centerOption="CenterOfBoundBox")
+        .center(-w / 2 + x_offset, -h / 2 + y_offset)
+        .placeSketch(shape)
+        .extrude(height)
+    )
+
+
+def punch_hole(*, model, face, w, h, x_offset, y_offset, hole, depth):
+    return (
+        model.faces(face)
+        .workplane(centerOption="CenterOfBoundBox")
+        .center(-w / 2 + x_offset + hole["x"], -h / 2 + y_offset + hole["y"])
+        .placeSketch(
+            cq.Sketch()
+            .trapezoid(hole["width"], hole["height"], 90, mode="a")
+            .vertices()
+            .fillet(hole["fillet"])
+        )
+        .cutBlind(-depth)
+    )

notebook_nueva/zero_holder.py

@@ -0,0 +1,16 @@
+import cadquery as cq
+
+positions = [(0, 0), (0, 23), (58, 23), (58, 0)]
+
+stands = cq.Sketch().push(positions).circle(3, mode="a").circle(2.65 / 2, mode="s")
+pillar_height = 7
+
+elements = [
+    # CPU holder stands
+    {
+        "x": 0,
+        "y": 0,
+        "shape": stands,
+        "height": pillar_height,
+    }
+]

requirements.txt

@@ -1 +1 @@
-cadquery
+cadquery2