remote-rig/hardware/case/tripod-case-v3.scad

// RemoteRig — Dual-ESP Tripod Case v3
// v3 changes: screw-tightened tripod clamp + dovetail slide interface.
// Coordinate system: all case/lid geometry uses bottom-origin Z.

$fn = 36;

// Board dimensions
esp8266_w = 34.2; esp8266_d = 25.6; esp8266_h = 5;
esp32_w   = 52;   esp32_d   = 28;   esp32_h   = 5;
board_gap = 3;
stack_h   = esp8266_h + esp32_h + board_gap;
inner_w   = max(esp8266_w, esp32_w);
inner_d   = max(esp8266_d, esp32_d);
inner_h   = stack_h + 2;

// Case parameters
wall     = 2.0;
tol      = 0.4;
outer_w  = inner_w + wall*2 + tol*2;      // 56.8mm
outer_d  = inner_d + wall*2 + tol*2;      // 32.8mm
outer_h  = inner_h + wall*2;              // 19mm
corner_r = 2.5;

// Tripod clamp parameters
pole_dia      = 35;       // nominal stand/pole diameter
clamp_thick   = 4.0;      // ring wall thickness
clamp_width   = 16.0;     // extrusion width along Z
mouth_width   = 13.0;     // clamp opening
m3_clearance  = 3.4;      // M3 screw clearance
nut_flat      = 6.4;      // M3 nut trap flat-to-flat

// Dovetail interface
rail_z        = outer_h * 0.78;
rail_depth    = 5.0;
rail_open_w   = 12.0;
rail_back_w   = 18.0;
rail_clearance = 0.35;

// Cable ports
usb_port_w = 12; usb_port_h = 6;
uart_port_w = 6; uart_port_h = 4;

// Uncomment one for manual OpenSCAD use
// full_case();
// case_body();
// case_lid();
// tripod_clamp();

module rounded_cube_centered(w, d, h, r) {
    hull() {
        for (x = [-1, 1], y = [-1, 1], z = [-1, 1]) {
            translate([x*(w/2 - r), y*(d/2 - r), z*(h/2 - r)])
                sphere(r=r, $fn=24);
        }
    }
}

module rounded_cube0(w, d, h, r) {
    translate([0, 0, h/2]) rounded_cube_centered(w, d, h, r);
}

module hex_prism(d, h) {
    cylinder(d=d, h=h, center=true, $fn=6);
}

module dovetail_prism(length_z, front_w, back_w, depth) {
    // 2D profile is X/Y, extruded along Z.
    rotate([0, 0, 0])
        linear_extrude(height=length_z, center=true, convexity=10)
            polygon(points=[
                [-front_w/2, 0], [front_w/2, 0],
                [back_w/2, depth], [-back_w/2, depth]
            ]);
}

module case_shell() {
    difference() {
        rounded_cube0(outer_w, outer_d, outer_h, corner_r);

        // Open internal cavity: starts above bottom wall, extends past top.
        translate([0, 0, wall])
            rounded_cube0(inner_w + tol, inner_d + tol, outer_h + 2, 1.6);

        // USB power IN / OUT ports through front/back walls.
        translate([0, outer_d/2 + 0.1, wall + 4])
            cube([usb_port_w, wall*3, usb_port_h], center=true);
        translate([0, -outer_d/2 - 0.1, wall + 4])
            cube([usb_port_w, wall*3, usb_port_h], center=true);

        // UART side channel.
        translate([outer_w/2 + 0.1, 0, wall + 6])
            cube([wall*3, uart_port_w, uart_port_h], center=true);

        // LED viewing window on front lower wall.
        translate([-outer_w/4, -outer_d/2 - 0.1, wall + 2])
            cube([6, wall*2, 3], center=true);
    }
}

module screw_post(x, y) {
    difference() {
        translate([x, y, wall]) cylinder(d=5.0, h=outer_h-wall-0.5, center=false, $fn=24);
        translate([x, y, wall-0.5]) cylinder(d=2.1, h=outer_h+1, center=false, $fn=20);
    }
}

module dovetail_socket_rails() {
    // Female-ish dovetail receiver on the case back. The clamp's male dovetail slides vertically.
    // Two angled lips are intentionally proud of the rear wall for printability and strength.
    for (side = [-1, 1]) {
        translate([side*(rail_open_w/2 + 1.3), outer_d/2 + 0.9, outer_h/2])
            rotate([0, 0, side*8])
                cube([3.0, rail_depth + 1.0, rail_z], center=true);
    }
    // Bottom stop so clamp cannot slide all the way through.
    translate([0, outer_d/2 + 1.3, outer_h*0.12])
        cube([rail_back_w + 2, rail_depth, 2.4], center=true);
}

module case_body() {
    union() {
        case_shell();
        for (x = [-1, 1], y = [-1, 1])
            screw_post(x*(outer_w/2 - 5), y*(outer_d/2 - 5));
        dovetail_socket_rails();
    }
}

module case_lid() {
    difference() {
        rounded_cube0(outer_w, outer_d, wall*2, 1.8);

        for (x = [-1, 1], y = [-1, 1]) {
            translate([x*(outer_w/2 - 5), y*(outer_d/2 - 5), -0.5])
                cylinder(d=2.4, h=wall*2 + 1, center=false, $fn=20);
        }

        for (x = [-outer_w/4, 0, outer_w/4]) {
            translate([x, 0, wall*2/2])
                cube([8, outer_d*0.6, wall*3], center=true);
        }
    }
}

module clamp_ring_with_mouth() {
    outer_r = pole_dia/2 + clamp_thick;
    difference() {
        cylinder(r=outer_r, h=clamp_width, center=true, $fn=72);
        cylinder(r=pole_dia/2 + rail_clearance, h=clamp_width + 1, center=true, $fn=72);
        // Mouth opens toward +Y. Width is intentionally generous for snap-on placement before tightening.
        translate([0, outer_r, 0])
            cube([mouth_width, outer_r*2, clamp_width + 2], center=true);
    }
}

module clamp_ears() {
    outer_r = pole_dia/2 + clamp_thick;
    ear_y = outer_r + 2.2;
    ear_z = 0;
    difference() {
        union() {
            translate([-mouth_width/2 - 3.2, ear_y, ear_z])
                rounded_cube_centered(7.0, 9.0, clamp_width, 1.4);
            translate([ mouth_width/2 + 3.2, ear_y, ear_z])
                rounded_cube_centered(7.0, 9.0, clamp_width, 1.4);
        }
        // M3 screw passes across the mouth along X.
        translate([0, ear_y, ear_z])
            rotate([0, 90, 0]) cylinder(d=m3_clearance, h=mouth_width + 24, center=true, $fn=24);
        // Nut trap on the right ear.
        translate([mouth_width/2 + 3.2, ear_y, ear_z])
            rotate([0, 90, 0]) hex_prism(nut_flat, 4.2);
    }
}

module male_dovetail_tab() {
    outer_r = pole_dia/2 + clamp_thick;
    // Tab on rear of clamp, opposite the mouth. Slides into case rails.
    translate([0, -outer_r - rail_depth + 0.4, 0])
        dovetail_prism(clamp_width, rail_open_w - rail_clearance, rail_back_w - rail_clearance, rail_depth);
}

module tripod_clamp() {
    union() {
        clamp_ring_with_mouth();
        clamp_ears();
        male_dovetail_tab();
    }
}

// Backward-compatible alias for earlier export scripts.
module tripod_clip() {
    tripod_clamp();
}

module full_case() {
    case_body();
    translate([0, 0, outer_h + 2]) case_lid();
    translate([0, outer_d/2 + pole_dia/2 + clamp_thick + 8, outer_h/2])
        rotate([90, 0, 0]) tripod_clamp();
}