Backpack Organizer v9: add shells.

backpack-organization/main-box.scad

@@ -6,15 +6,20 @@ $fn=128;
 outerWall=4;
 innerWall=2;
 layerClearance = 0.5;
-verStr="v8";
+verStr="v9";
 font="Montserrat";
+ep = 0.01; // smallest unit to ensure overlap between shapes
 
 // as a convention, outer dimensions refer to measurements from outside wall to
 // outside wall, as if you put a caliper around the whole thing. Inner
 // dimesions refers to inside or void dimensions: the space available to be
 // filled.
+layer1H = 44;
+layer2H = 40;
+
 outerBoxLength = 300;
 outerBoxWidth = 154;
+outerBoxHeight = layer1H + layer2H + 2*outerWall;
 
 innerBoxLength = outerBoxLength - 2*outerWall;
 innerBoxWidth = outerBoxWidth - 2*outerWall;
@@ -25,8 +30,114 @@ audioTrayIS = audioTraySide - 2*innerWall;
 audioTrayIH = audioTrayHeight - innerWall;
 
 
+module shellBottom(dims) {
+  lipClearance = innerWall + 1;
+  bottomShellH = dims[2]*0.75;
+  difference() {
+    union() {
+      difference() {
+        // main body
+        chamferedCube(dims,
+          chamfer=4);
+
+        // top-cut (75% up)
+        translate([-outerWall, -outerWall, bottomShellH])
+        cube([dims[0] + 2*outerWall, dims[1] + 2*outerWall, dims[2]]);
+      }
+
+      // add lip to mate with top
+      translate([lipClearance, lipClearance, bottomShellH - ep])
+      roundedCube(
+        [dims[0] - 2*lipClearance, dims[1] - 2*lipClearance, 4 - 1],
+        [2, 2, 0]);
+    }
+
+    // carve out the interior
+    translate([outerWall, outerWall, outerWall])
+    cube([dims[0] - 2*outerWall, dims[1] - 2*outerWall, dims[2]]);
+
+    // carve out a 0.6mm sliver for the fabric to sit in
+    fabricClearance = 0.6;
+    translate([
+      lipClearance - fabricClearance,
+      lipClearance - fabricClearance,
+      bottomShellH - 4])
+    difference() {
+      roundedCube(
+        [ dims[0] - 2*lipClearance + 2*fabricClearance,
+          dims[1] - 2*lipClearance + 2*fabricClearance,
+          7],
+        [2, 2, 0]);
+
+      translate([fabricClearance, fabricClearance, -ep])
+      roundedCube(
+        [dims[0] - 2*lipClearance, dims[1] - 2*lipClearance, 8],
+        [2, 2, 0]);
+    }
+
+    // version marker
+    color("black")
+    translate([0.6, 20, 8]) rotate([90, 0,-90])
+    linear_extrude(0.61) text(text = verStr, font = font, size = 8);
+  }
+}
+
+module shellTop(dims) {
+  lipClearance = innerWall + 1;
+  topShellH = dims[2]*0.25;
+  difference() {
+    union() {
+      difference() {
+        // main body
+        chamferedCube(dims,
+          chamfer=4);
+
+        // top-cut (75% up)
+        translate([-outerWall, -outerWall, topShellH + 4])
+        cube([dims[0] + 2*outerWall, dims[1] + 2*outerWall, dims[2]]);
+      }
+    }
+
+    // carve out the interior
+    translate([outerWall, outerWall, outerWall])
+    cube([dims[0] - 2*outerWall, dims[1] - 2*outerWall, dims[2]]);
+
+    // carve out the interior of the lip
+    translate([lipClearance, lipClearance, topShellH])
+    roundedCube(
+      [dims[0] - 2*lipClearance, dims[1] - 2*lipClearance, dims[2]],
+      [2, 2, 0]);
+
+    // carve out a 0.6mm sliver for the fabric to sit in
+    fabricClearance = 0.6;
+    translate([
+      lipClearance,
+      lipClearance,
+      topShellH - 4])
+    difference() {
+      roundedCube(
+        [ dims[0] - 2*lipClearance,
+          dims[1] - 2*lipClearance,
+          7],
+        [2, 2, 0]);
+
+      translate([fabricClearance, fabricClearance, -ep])
+      roundedCube(
+        [ dims[0] - 2*lipClearance - 2*fabricClearance,
+          dims[1] - 2*lipClearance - 2*fabricClearance,
+          8],
+        [2, 2, 0]);
+    }
+
+    // version marker
+    color("black")
+    translate([0.6, 20, 8]) rotate([90, 0,-90])
+    linear_extrude(0.61) text(text = verStr, font = font, size = 8);
+  }
+}
+
 module layer1() {
-  oH = 44;
+  oH = layer1H;
   oL = innerBoxLength - 2*layerClearance;  // outer length
   oW = innerBoxWidth - 2*layerClearance;   // outer width
   iL = oL - 2*innerWall;              // inner length
@@ -66,7 +177,7 @@ module layer1() {
         // plain cube version (we're going to oversize and chamfer to get
         // diagonal edges)
         // translate([(handleDia - bitW) / 2, handleDia / 2, 0]) cube([bitW, bitL + handleDia/2, oH]);
-        translate([(handleDia - bitW) / 2 - 5, handleDia / 2 - 5, -0.01])
+        translate([(handleDia - bitW) / 2 - 5, handleDia / 2 - 5, -ep])
         chamferedCube([bitW + 10, bitL + handleDia/2 + 10, 16], chamfer=5);
 
         // power block cutout
@@ -139,7 +250,7 @@ module layer1() {
 }
 
 module layer2() {
-  oH = 40;
+  oH = layer2H;
   oL = innerBoxLength - 2*layerClearance;  // outer length
   oW = innerBoxWidth - 2*layerClearance;   // outer width
   iL = oL - 2*innerWall;              // inner length
@@ -159,21 +270,21 @@ module layer2() {
 
         // Tekton tool kit
         translate([2, 103 + innerWall, 0])
-        cube([105.5, 57, oH]);
+        cube([105.5, 61, oH]);
 
         // Slice knife
         translate([114, 103 + innerWall, 0])
-        cube([22.5, 153, oH]);
+        cube([22.5, 156, oH]);
 
         // cables
-        translate([56, 224, 0])
+        translate([56, 226, 0])
         cylinder(d=110, h=oH);
 
         // fingerways
         translate([30, 80, 0])
         cube([36, 30, oH]);
 
-        translate([105, 126, 0])
+        translate([105, 130, 0])
         cube([12, 36, oH]);
       }
 
@@ -185,7 +296,7 @@ module layer2() {
 
     translate([32, 96, 0]) scale([6, 22, 1]) cylinder(d=1, h=oH);
     translate([68, 96, 0]) scale([6, 22, 1]) cylinder(d=1, h=oH);
-    translate([112.75, 128, 0]) scale([6.5, 6, 1]) cylinder(d=1, h=oH);
+    translate([112.75, 132, 0]) scale([6.5, 6, 1]) cylinder(d=1, h=oH);
   }
 }
 
@@ -426,9 +537,19 @@ module usbBitsTray() {
   }
 }
 
-layer1();
+standoffX = outerBoxWidth + 10;
-//layer2();
+standoffY = outerBoxLength + 10;
-//translate([outerBoxWidth + 10, 0, 0]) audioJackTray();
+
-//translate([outerBoxWidth + 10, 80, 0]) usbBitsTray();
+// test-print the lip
-//translate([outerBoxWidth + 10, 160, 0]) headphoneAmpTray();
+shellBottom([20, 30, 30]);
-//translate([outerBoxWidth + 10, 240, 0]) drumKeyTray();
+translate([24, 0, 0]) shellTop([20, 30, 30]);
+/*
+shellBottom([outerBoxWidth, outerBoxLength, outerBoxHeight]);
+translate([0, standoffY, 0]) shellTop([outerBoxWidth, outerBoxLength, outerBoxHeight]);
+translate([standoffX, 0, 0]) layer1();
+translate([standoffX, standoffY, 0]) layer2();
+translate([2*standoffX, 0, 0]) audioJackTray();
+translate([2*standoffX, 80, 0]) usbBitsTray();
+translate([2*standoffX, 160, 0]) headphoneAmpTray();
+translate([2*standoffX, 240, 0]) drumKeyTray();
+*/