cyberdeck-k42/cad/display-frame.scad

$fn=32*2;
thickness=1.6;
width=208.2;
depth=70.2;
height=8;

display_frame();
module display_frame(){
  difference(){
    // main frame
    translate([0, 0, 0])
      cube([width+(thickness*2), depth+(thickness*2), height+20]);
    translate([thickness, thickness, 0])
      cube([width, depth, height+20]);
    
    // hdmi gap
    translate([thickness+95, depth+thickness, height])
      cube([25, 0.8, 17]);
    
    // usb cutouts
    translate([0, 47.5, height+thickness+8.5])
      cube([thickness, 14, 6.5]);
    
    translate([0.8, 46.5, height+thickness])
      cube([thickness, 16, 8]);
    
    // usb-c
    translate([0, 35, height+thickness+8])
      hull(){
        translate([0, 0, 2])
          rotate([0, 90, 0])
            cylinder(h=thickness, d=4);
        cube([thickness, 7, 4]);
        translate([0, 7, 2])
          rotate([0, 90, 0])
            cylinder(h=thickness, d=4);
      }
      
    // micro usb
    translate([0, 22.5, height+thickness+8])
      cube([thickness, 8, 3.5]);
      
    // data cables
    translate([(width+(thickness*2))/2-25, 0, 19])
      rotate([-90, 0, 0])
        cylinder(h=thickness, d=3.5);
      
    translate([(width+(thickness*2))/2+25, 0, 19])
      rotate([-90, 0, 0])
        cylinder(h=thickness, d=3.5);
      
    // lid mounting holes
    translate([thickness+30, 0, 23])
      rotate([-90, 0, 0])
        cylinder(h=depth+(thickness*2), d=2);
      
    translate([width+thickness-30, 0, 23])
      rotate([-90, 0, 0])
        cylinder(h=depth+(thickness*2), d=2);
  }
  
  // inner display catch
  translate([thickness, thickness, 1.5]){
    padding=5;
    ledge=0.8;
    difference(){
      translate([padding, 0, 0])
        cube([width-(padding*2), depth, thickness]);
      translate([0, ledge, 0])
        cube([width, depth-(ledge*2), thickness]);
    }
    
    // hinge support
    translate([5, -0.6, 0])
      cube([width-10, thickness, 15]);
  }
  
  // usb compartment
  translate([0, 0, 0])
    usb_compartment();

  // battery compartment
  translate([146.6, 0, 0])
    battery_compartment();

  // display hinge
  translate([(width+thickness*2)/2, -9, 6.57])
    rotate([90, 270, 0])
      male_hinge();
}

module usb_compartment(){
  usb_width=41;
  usb_height=4;
  hole=6;
  hole_x=36+thickness;
  hole_y=5.6+thickness;

  difference(){
    translate([0, 0, height])
      cube([usb_width+thickness, depth+(thickness*2), usb_height+thickness]);

    translate([0, thickness, height+thickness])
      cube([30, depth, usb_height]);
    
    translate([30+thickness, thickness, height])
      cube([11, depth, usb_height]);
    
    translate([hole_x, hole_y-0.5, height+usb_height])
      cylinder(h=thickness, d=hole);

    translate([hole_x-0.5, depth+(thickness*2)-hole_y, height+usb_height])
      cylinder(h=thickness, d=hole);
  }
  
  // pcb mount
  translate([thickness+12, 12, height+thickness])
    difference(){
      cylinder(h=7, d=4);
      cylinder(h=7, d=1.6);
    }
  
  translate([thickness+7, 30.8, height+thickness])
    difference(){
      cylinder(h=7, d=4);
      cylinder(h=7, d=1.6);
    }
  
  translate([thickness+11.8, 42.8, height+thickness])
    difference(){
      cylinder(h=7, d=4);
      cylinder(h=7, d=1.6);
    }
  
  translate([thickness+10.5, 7.1, height+thickness])
    cube([3, thickness, 10]);
    
  translate([thickness+11.25, 5.1, height+thickness])
    cube([thickness, 3, 10]);
  
  translate([thickness+10.5, 62.1, height+thickness])
    cube([3, thickness, 10]);
    
  translate([thickness+11.25, 62.6, height+thickness])
    cube([thickness, 3, 10]);
  
  // screw mount
  translate([hole_x, hole_y-0.5, height+4+thickness]){
    difference(){
       cylinder(h=1.6, d=10);
       cylinder(h=1.6, d=2.5);
    }
  }
  
  translate([hole_x-0.5, depth+(thickness*2)-hole_y, height+4+thickness]){
    difference(){
       cylinder(h=1.6, d=10);
       cylinder(h=1.6, d=2.5);
    }
  }
}

module battery_compartment(){
    battery_width=63.2;
    battery_height=4;
    hole=6;
    hole_x=5;
    hole_y=5.6+thickness;

    difference(){
      translate([0, 0, height])
        cube([battery_width+thickness, depth+(thickness*2), battery_height+thickness]);

      translate([0, thickness, height])
        cube([battery_width, depth, battery_height]);

      translate([hole_x, hole_y-0.5, height+4])
        cylinder(h=thickness, d=hole);

      translate([hole_x, depth+(thickness*2)-hole_y, height+battery_height])
        cylinder(h=thickness, d=hole);
    }
    
    // battery stop
    translate([-1.2, (depth+(thickness*2))/2-5, height+battery_height])
      cube([thickness, 10, 16]);
    
    // screw mount
    translate([hole_x, hole_y-0.5, height+4+thickness]){
      difference(){
         cylinder(h=1.6, d=10);
         cylinder(h=1.6, d=2.5);
      }
    }
    
    translate([hole_x, depth+(thickness*2)-hole_y, height+4+thickness]){
      difference(){
         cylinder(h=1.6, d=10);
         cylinder(h=1.6, d=2.5);
      }
    }
}

module tab(length, thickness){
  difference(){
    union(){
      translate([0,0,-5])
        cube([length, thickness, 10], center=true);

        rotate([90,0,0])
          cylinder(h=thickness, d=length, center=true);
      }

      rotate([90,0,0])
        cylinder(h=20, d=5, center=true);
    }
}

module male_hinge(){
  th=2.90;  //Thickness of solid tabs
  sp=3.10;  //Width of seperation gap
  w=20.94;  //Width of base
  l=13.14;  //length of base

  translate([0, 0, -10+th/2]){
    hull(){
      cube([l, w, th], center=true);

      translate([-l/2, -w/2-4, -2])
        cube([l+4, w+8, 0.1]);
    }
  }

  //generating 3 tabs with sp spacing
  translate([0, -sp*2, 0])
    tab(l, th);
  translate([0, sp*2, 0])
    tab(l, th);
  translate([0, 0, 0])
    tab(l, th);
}