--- /dev/null
+// -*- mode: c -*-
+/* All distances are in mm. */
+
+/* set output quality */
+$fn = 50;
+
+/* Distance between key centers. */
+column_spacing = 19;
+row_spacing = column_spacing;
+
+/* This number should exceed row_spacing and column_spacing. The
+ default gives a 1mm = (20mm - 19mm) gap between keycaps and cuts in
+ the top plate.*/
+key_hole_size = 20;
+
+/* rotation angle; the angle between the halves is twice this
+ number */
+angle = 10;
+
+/* The radius of screw holes. Holes will be slightly bigger due
+ to the cut width. */
+screw_hole_radius = 1.5;
+/* Each screw hole is a hole in a "washer". How big these "washers"
+ should be depends on the material used: this parameter and the
+ `switch_hole_size` determine the spacer wall thickness. */
+washer_radius = 4 * screw_hole_radius;
+
+/* This constant allows tweaking the location of the screw holes near
+ the USB cable. Only useful with small `angle` values. Try the value
+ of 10 with angle=0. */
+back_screw_hole_offset = 0;
+
+/* Distance between halves. */
+hand_separation = 0;
+
+/* The approximate size of switch holes. Used to determine how
+ thick walls can be, i.e. how much room around each switch hole to
+ leave. See spacer(). */
+switch_hole_size = 14;
+
+/* Sets whether the case should use notched holes. As far as I can
+ tell these notches are not all that useful... */
+use_notched_holes = true;
+
+/* Number of rows and columns in the matrix. You need to update
+ staggering_offsets if you change n_cols. */
+n_rows = 4;
+n_cols = 5;
+
+/* Number of thumb keys (per hand), try 1 or 2. */
+n_thumb_keys = 1;
+
+/* The width of the USB cable hole in the spacer. */
+cable_hole_width = 12;
+
+/* Vertical column staggering offsets. The first element should
+ be zero. */
+staggering_offsets = [0, 5, 11, 6, 3];
+
+/* Whether or not to split the spacer into quarters. */
+quarter_spacer = false;
+
+/* Where the top/bottom split of a quartered spacer will be. */
+spacer_quartering_offset = 60;
+
+module rz(angle, center=undef) {
+ /* Rotate children `angle` degrees around `center`. */
+ translate(center) {
+ rotate(angle) {
+ translate(-center) {
+ for (i=[0:$children-1])
+ children(i);
+ }
+ }
+ }
+}
+
+/* Compute coordinates of a point obtained by rotating p angle degrees
+ around center. Used to compute locations of screw holes near the
+ USB cable hole. */
+function rz_fun(p, angle, center) = [cos(angle) * (p[0] - center[0]) - sin(angle) * (p[1] - center[1]) + center[0],
+ sin(angle) * (p[0] - center[0]) + cos(angle) * (p[1] - center[1])+ center[1]];
+
+module switch_hole(position, notches=use_notched_holes) {
+ /* Cherry MX switch hole with the center at `position`. Sizes come
+ from the ErgoDox design. */
+ hole_size = 13.97;
+ notch_width = 3.5001;
+ notch_offset = 4.2545;
+ notch_depth = 0.8128;
+ translate(position) {
+ union() {
+ square([hole_size, hole_size], center=true);
+ if (notches == true) {
+ translate([0, notch_offset]) {
+ square([hole_size+2*notch_depth, notch_width], center=true);
+ }
+ translate([0, -notch_offset]) {
+ square([hole_size+2*notch_depth, notch_width], center=true);
+ }
+ }
+ }
+ }
+};
+
+module regular_key(position, size) {
+ /* Create a hole for a regular key. */
+ translate(position) {
+ square([size, size], center=true);
+ }
+}
+
+module thumb_key(position, size) {
+ /* Create a hole for a 1x1.5 unit thumb key. */
+ translate(position) {
+ scale([1, 1.5]) {
+ translate(-position) {
+ regular_key(position, size);
+ }
+ }
+ }
+}
+
+module column (bottom_position, switch_holes, key_size=key_hole_size) {
+ /* Create a column of keys. */
+ translate(bottom_position) {
+ for (i = [0:(n_rows-1)]) {
+ if (switch_holes == true) {
+ switch_hole([0, i*column_spacing]);
+ } else {
+ regular_key([0, i*column_spacing], key_size);
+ }
+ }
+ }
+}
+
+module rotate_half() {
+ /* Rotate the right half of the keys around the top left corner of
+ the thumb key. Assumes that the thumb key is a 1x1.5 key and that
+ it is shifted 0.5*column_spacing up relative to the nearest column. */
+ rotation_y_offset = 1.75 * column_spacing;
+ for (i=[0:$children-1]) {
+ rz(angle, [hand_separation, rotation_y_offset]) {
+ children(i);
+ }
+ }
+}
+
+module add_hand_separation() {
+ /* Shift everything right to get desired hand separation. */
+ for (i=[0:$children-1]) {
+ translate([0.5*hand_separation, /* we get back the full separation
+ because of mirroring */
+ 0]) children(i);
+ }
+}
+
+module right_half (switch_holes=true, key_size=key_hole_size) {
+ /* Create switch holes or key holes for the right half of the
+ keyboard. Different key_sizes are used in top_plate() and
+ spacer(). */
+ x_offset = 0.5 * row_spacing;
+ y_offset = 0.5 * column_spacing;
+ thumb_key_offset = y_offset + 0.5 * column_spacing;
+ rotate_half() {
+ add_hand_separation() {
+ for (j=[0:(n_thumb_keys-1)]) {
+ if (switch_holes == true) {
+ switch_hole([x_offset + j*row_spacing, thumb_key_offset]);
+ } else {
+ thumb_key([x_offset + j*row_spacing, thumb_key_offset], key_size);
+ }
+ }
+ for (j=[0:(n_cols-1)]) {
+ column([x_offset + (j+n_thumb_keys)*row_spacing, y_offset + staggering_offsets[j]], switch_holes, key_size);
+ }
+ }
+ }
+}
+
+module screw_hole(radius, offset_radius, position, direction) {
+ /* Create a screw hole of radius `radius` at a location
+ `offset_radius` from `position`, (diagonally), in the direction
+ `direction`. Oh, what a mess this is. */
+ /* direction is the 2-element vector specifying to which side of
+ position to move to, [-1, -1] for bottom left, etc. */
+
+ /* radius_offset is the offset in the x (or y) direction so that
+ we're offset_radius from position */
+ radius_offset = offset_radius / sqrt(2);
+ /* key_hole_offset if the difference between key spacing and key
+ hole edge */
+ key_hole_offset = 0.5*(row_spacing - key_hole_size);
+ x = position[0] + (radius_offset - key_hole_offset) * direction[0];
+ y = position[1] + (radius_offset - key_hole_offset) * direction[1];
+ translate([x,y]) {
+ circle(radius);
+ }
+}
+
+module right_screw_holes(hole_radius) {
+ /* coordinates of the back right screw hole before rotation... */
+ back_right = [(n_cols+n_thumb_keys)*row_spacing,
+ staggering_offsets[n_cols-1] + n_rows * column_spacing];
+ /* and after */
+ tmp = rz_fun(back_right, angle, [0, 2.25*column_spacing]);
+
+ nudge = 0.75;
+
+ rotate_half() {
+ add_hand_separation() {
+ screw_hole(hole_radius, washer_radius,
+ [row_spacing, 0],
+ [-nudge, -nudge]);
+ screw_hole(hole_radius, washer_radius,
+ [(n_cols+n_thumb_keys)*row_spacing, staggering_offsets[n_cols-1]],
+ [nudge, -nudge]);
+ screw_hole(hole_radius, washer_radius,
+ back_right,
+ [nudge, nudge]);
+ }
+ }
+
+ /* add the screw hole near the cable hole */
+ translate([washer_radius - tmp[0] - 0.5*hand_separation,
+ back_screw_hole_offset]) {
+ rotate_half() {
+ add_hand_separation() {
+ screw_hole(hole_radius,
+ washer_radius,
+ back_right,
+ [nudge, nudge]);
+ }
+ }
+ }
+}
+
+module screw_holes(hole_radius) {
+ /* Create all the screw holes. */
+ right_screw_holes(hole_radius);
+ mirror ([1,0,0]) { right_screw_holes(hole_radius); }
+}
+
+module left_half(switch_holes=true, key_size=key_hole_size) {
+ mirror ([1,0,0]) { right_half(switch_holes, key_size); }
+}
+
+module bottom_plate() {
+ /* bottom layer of the case */
+ difference() {
+ hull() { screw_holes(washer_radius); }
+ screw_holes(screw_hole_radius);
+ }
+}
+
+module top_plate() {
+ /* top layer of the case */
+ difference() {
+ bottom_plate();
+ right_half(false);
+ left_half(false);
+ }
+}
+
+module switch_plate() {
+ /* the switch plate */
+ difference() {
+ bottom_plate();
+ right_half();
+ left_half();
+ }
+}
+
+module spacer() {
+ /* Create a spacer. */
+ difference() {
+ union() {
+ difference() {
+ bottom_plate();
+ hull() {
+ right_half(switch_holes=false, key_size=switch_hole_size + 3);
+ left_half(switch_holes=false, key_size=switch_hole_size + 3);
+ }
+ /* add the USB cable hole: */
+ translate([-0.5*cable_hole_width, 2*column_spacing]) {
+ square([cable_hole_width, (2*n_rows) * column_spacing]);
+ }
+ }
+ screw_holes(washer_radius);
+ }
+ screw_holes(screw_hole_radius);
+ }
+}
+
+module spacer_quadrant(spacer_quadrant_number) {
+ /* Cut a quarter of a spacer. */
+ translate([0, spacer_quartering_offset]) {
+ intersection() {
+ translate([0, -spacer_quartering_offset]) { spacer(); }
+ rotate([0, 0, spacer_quadrant_number * 90]) { square([1000, 1000]); }
+ }
+ }
+}
+
+module quartered_spacer()
+{
+ /* Assemble all four quarters of a spacer. */
+ spacer_quadrant(0);
+ spacer_quadrant(1);
+ translate([-5,-10]) spacer_quadrant(2);
+ translate([5,-10]) spacer_quadrant(3);
+}
+
+/* Create all four layers. */
+top_plate();
+translate([300, 0]) { switch_plate(); }
+translate([0, 150]) { bottom_plate(); }
+translate([300, 150]) {
+ if (quarter_spacer == true) {
+ quartered_spacer();
+ }
+ else {
+ spacer();
+ }
+}
projects / atreides.git / blobdiff