PSU Enclosure: WiP

.gitmodules

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+[submodule "MCAD"]
+	path = 013-PSU-Enclosure/MCAD
+	url = https://github.com/openscad/MCAD.git
+[submodule "013-PSU-Enclosure/OpenSCAD-Pattern-Filling"]
+	path = 013-PSU-Enclosure/OpenSCAD-Pattern-Filling
+	url = https://github.com/nmasse-itix/OpenSCAD-Pattern-Filling.git
+	branch = 1.0

013-PSU-Enclosure/MCAD

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+Subproject commit 0e57f5500adeec9e3b23139947c98f0426db358b

013-PSU-Enclosure/OpenSCAD-Pattern-Filling

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+Subproject commit 24b508235e83eac7abc1875a060be34439f3eab6

013-PSU-Enclosure/psu-enclosure.scad

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+
+include <MCAD/units.scad>;
+use <OpenSCAD-Pattern-Filling/pattern.scad>;
+
+$fn = 36;
+useful_size = [ 14 * cm, 17 * cm, 9 * cm ];
+wall_size = 3 * mm;
+round_radius = 3 * mm;
+
+// Vent Parameters
+vent_alveolus_size = 8 * mm;
+vent_margin = 1 * mm;
+vent_xstep = cos(30) * (vent_margin + sqrt(3) * vent_alveolus_size / 2);
+vent_ystep = sin(30) * (vent_margin + sqrt(3) * vent_alveolus_size / 2);
+
+module box(useful_size, wall_size) {
+  difference() {
+    translate([ -wall_size, -wall_size, -wall_size ])
+      cube([ useful_size.x + 2 * wall_size, useful_size.y + 2 * wall_size, useful_size.z + wall_size ]);
+    translate([ 0, 0, epsilon])
+      cube([ useful_size.x, useful_size.y, useful_size.z ]);
+  }
+}
+
+module rounded_corner(round_radius, length) {
+  difference() {
+    cube([ round_radius, round_radius, length ]);
+    translate([ round_radius, round_radius, -epsilon ])
+      cylinder(r=round_radius, h=length + 2 * epsilon);
+  }
+}
+
+module at_four_corners(box) {
+  translate([ box[0].x, box[0].y, 0 ])
+      children();
+  translate([ box[1].x, box[0].y, 0 ])
+    rotate([ 0, 0, 90 ])
+      children();
+  translate([ box[1].x, box[1].y, 0 ])
+    rotate([ 0, 0, 180 ])
+      children();
+  translate([ box[0].x, box[1].y, 0 ])
+    rotate([ 0, 0, 270 ])
+      children();
+}
+
+module rounded_box(useful_size, wall_size, round_radius) {
+  difference() {
+    union() {
+      box(useful_size, wall_size);
+      at_four_corners([ [ 0, 0 ], useful_size ])
+        rounded_corner(round_radius, useful_size.z);
+    }
+    at_four_corners([ [ -wall_size, -wall_size ], useful_size + [ wall_size, wall_size ] ])
+      translate([ -epsilon, -epsilon, -wall_size - epsilon ])
+        rounded_corner(round_radius, useful_size.z + wall_size + 2 * epsilon);
+  }
+}
+
+difference() {
+  rounded_box(useful_size, wall_size, round_radius);
+
+  // Main socket
+  socket_position = [ 0, -133 * mm, 20 * mm ];
+  socket_dimension = [ wall_size + 2 * epsilon, 31 * mm, 22 * mm ];
+  socket_mounting_holes_diameter = 2.5 * mm;
+  socket_mounting_holes_position = [ 0, - 4.5 * mm, socket_dimension.z / 2 ];
+  translate([ -wall_size - epsilon + socket_position.x, useful_size.y + socket_position.y, socket_position.z ]) {
+    cube(socket_dimension);
+    translate(socket_mounting_holes_position)
+      rotate([ 0, 90, 0 ])
+        cylinder(d = socket_mounting_holes_diameter, h = wall_size + 2 * epsilon);
+    translate([ socket_mounting_holes_position.x, socket_dimension.y - socket_mounting_holes_position.y, socket_mounting_holes_position.z ] )
+      rotate([ 0, 90, 0 ])
+        cylinder(d = socket_mounting_holes_diameter, h = wall_size + 2 * epsilon);
+  }
+
+  // Main switch
+  switch_position = [ 0, -127 * mm, 60 * mm ];
+  switch_dimension = [ wall_size + 2 * epsilon, 19 * mm, 13 * mm ];
+  translate([ -wall_size - epsilon + switch_position.x, useful_size.y + switch_position.y, switch_position.z ]) {
+    cube(switch_dimension);
+  }
+
+  // Fan vent
+  fan_vent_size = [ 76.5 * mm, 76.5 * mm, wall_size + 2 * epsilon ];
+  fan_vent_position = [ 10 * mm, 5 * mm ];
+  fan_vent_diameter = 90 * mm;
+  fan_vent_mounting_hole_position = [ 36 * mm, 36 * mm ];
+  fan_vent_mounting_hole_diameter = 5.5 * mm;
+  translate([ -wall_size - epsilon, useful_size.y - fan_vent_position.x - fan_vent_size.x / 2, fan_vent_position.y + fan_vent_size.y / 2 ])
+  rotate([ 0, 90, 0 ]) {
+    intersection() {
+      translate(-[ fan_vent_size.x, fan_vent_size.y] / 2)
+        cube(fan_vent_size);
+      cylinder(d = fan_vent_diameter, h = wall_size + 2 * epsilon, $fn = 180);
+      spray_pattern([ fan_vent_size / -2, fan_vent_size / 2 ], [ [ 2 * vent_xstep, 0 ], [ vent_xstep, vent_ystep ] ]) {
+        cylinder(d = vent_alveolus_size, h = wall_size + 2 * epsilon, $fn = 6);
+      }
+    }
+
+    at_four_corners([ -fan_vent_mounting_hole_position, fan_vent_mounting_hole_position ])
+      cylinder(d = fan_vent_mounting_hole_diameter, h = wall_size + 2 * epsilon);
+  }
+
+  // Back vents
+  back_vent_crop = [ 10 * mm, 10 * mm ];
+  back_vent_size = [ useful_size.y - 2 * back_vent_crop.x, useful_size.z - 2 * back_vent_crop.y ];
+  translate([ useful_size.x - epsilon, 0, 0 ])
+  rotate([ 0, 0, 180 ])
+  rotate([ 0, -90, 0 ])
+  rotate([ 0, 0, -90 ])
+  spray_pattern([ back_vent_crop, back_vent_size + back_vent_crop ], [ [ 2 * vent_xstep, 0 ], [ vent_xstep, vent_ystep ] ]) {
+    cylinder(d = vent_alveolus_size, h = wall_size + 2 * epsilon, $fn = 6);
+  }
+
+}