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

// RemoteRig — Dual-ESP Tripod Case
// =================================
// Small box that clips onto a tripod leg or light stand pole.
// Holds ESP8266 D1 Mini + ESP32 Dev Board (stacked).
// Powered by standard USB battery pack. No camera sleeve needed.
//
// Print settings:
//   Material: PETG | Layer: 0.2mm | Infill: 20% gyroid
//   Supports: yes (for clip overhang) | Brim: 5mm

// ── 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; // air gap between stacked boards
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;
outer_d  = inner_d + wall*2 + tol*2;
outer_h  = inner_h + wall*2;

// ── Tripod clip parameters ──
pole_min_dia = 20;  // smallest pole
pole_max_dia = 35;  // largest pole
clip_width   = 12;  // clip width
clip_thick   = 3;   // clip arm thickness
clip_grip    = 2;   // grip ridges

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

// ══════════════════════════════════════════════════════════════
// MAIN — render the full case
// ══════════════════════════════════════════════════════════════

// Uncomment to render individual parts:
full_case();
// case_body();
// case_lid();
// tripod_clip();

module full_case() {
    case_body();
    // Lid positioned above (for visualization)
    translate([0, 0, outer_h + 2])
    case_lid();
    // Clip on the back
    translate([0, outer_d/2 + pole_max_dia/2 + clip_thick, outer_h/2])
    tripod_clip();
}

// ══════════════════════════════════════════════════════════════
// Case Body — holds both boards, cable ports
// ══════════════════════════════════════════════════════════════

module case_body() {
    difference() {
        // Outer shell
        rounded_cube(outer_w, outer_d, outer_h, 3);
        
        // Inner cavity
        translate([0, 0, wall])
        rounded_cube(inner_w + tol, inner_d + tol, inner_h + tol, 2);
        
        // ── Board recesses ──
        
        // Bottom: ESP32 (larger board)
        translate([0, 0, wall + 1])
        cube([esp32_w + tol, esp32_d + tol, esp32_h + 1], center=true);
        
        // Top: ESP8266 (smaller board)
        translate([0, 0, wall + esp32_h + board_gap + 1])
        cube([esp8266_w + tol, esp8266_d + tol, esp8266_h + 1], center=true);
        
        // ── Cable ports ──
        
        // USB power IN (from battery pack → ESP32)
        translate([0, outer_d/2, outer_h/3])
        cube([usb_port_w, wall*3, usb_port_h], center=true);
        
        // USB power OUT (from battery pack → GoPro)
        translate([0, -outer_d/2, outer_h/3])
        cube([usb_port_w, wall*3, usb_port_h], center=true);
        
        // UART wire channel (ESP8266 → ESP32 internal)
        translate([outer_w/2, 0, outer_h/2])
        cube([wall*3, uart_port_w, uart_port_h], center=true);
        
        // ── Ventilation slots (top edge) ──
        for (x = [-outer_w/4, 0, outer_w/4]) {
            translate([x, 0, outer_h - wall])
            cube([8, outer_d*0.6, 2], center=true);
        }
        
        // ── Screw posts for lid ──
        for (x = [-1, 1], y = [-1, 1]) {
            translate([x*(outer_w/2 - 5), y*(outer_d/2 - 5), outer_h/2])
            cylinder(d=3.2, h=outer_h, center=true, $fn=16);
        }
        
        // ── LED window (thin spot to see board LEDs) ──
        translate([-outer_w/4, -outer_d/2, wall])
        cube([6, 1, 3], center=true);
    }
    
    // ── Tripod clip mount (rail on back) ──
    translate([0, outer_d/2, outer_h/2])
    rotate([90, 0, 0])
    difference() {
        cube([clip_width + 4, outer_h*0.7, 6], center=true);
        // T-slot for clip to slide in
        cube([clip_width + 1, outer_h*0.7 + 1, 4], center=true);
    }
}

// ══════════════════════════════════════════════════════════════
// Case Lid — snap-fit or screw-on cover
// ══════════════════════════════════════════════════════════════

module case_lid() {
    difference() {
        rounded_cube(outer_w, outer_d, wall*2, 2);
        
        // Screw holes (match body posts)
        for (x = [-1, 1], y = [-1, 1]) {
            translate([x*(outer_w/2 - 5), y*(outer_d/2 - 5), 0])
            cylinder(d=3.2, h=wall*3, center=true, $fn=16);
        }
        
        // Ventilation slots (match body)
        for (x = [-outer_w/4, 0, outer_w/4]) {
            translate([x, 0, 0])
            cube([8, outer_d*0.6, 3], center=true);
        }
    }
}

// ══════════════════════════════════════════════════════════════
// Tripod Clip — C-clamp for pole mounting
// ══════════════════════════════════════════════════════════════

module tripod_clip() {
    difference() {
        union() {
            // Main body
            hull() {
                translate([0, -pole_max_dia/2 - clip_thick, 0])
                cube([clip_width, clip_thick*2, outer_h*0.7], center=true);
                
                translate([0, pole_max_dia/2 + clip_thick, 0])
                cube([clip_width, clip_thick*2, outer_h*0.7], center=true);
            }
            
            // Top arm (flexible)
            translate([0, -pole_max_dia/2 - clip_thick, outer_h*0.35])
            cube([clip_width, pole_max_dia + clip_thick*4, clip_thick], center=true);
            
            // Bottom arm
            translate([0, -pole_max_dia/2 - clip_thick, -outer_h*0.35])
            cube([clip_width, pole_max_dia + clip_thick*4, clip_thick], center=true);
            
            // Mounting tab (slides into case rail)
            translate([0, -pole_max_dia/2 - clip_thick*3, 0])
            cube([clip_width + 1, clip_thick*2, outer_h*0.7], center=true);
        }
        
        // Pole hole
        cylinder(d=pole_max_dia + 2, h=outer_h*1.5, center=true, $fn=32);
        
        // Grip ridges on inner surface
        for (z = [-outer_h*0.25, 0, outer_h*0.25]) {
            translate([0, 0, z])
            rotate_extrude(angle=180, $fn=32)
            translate([pole_max_dia/2 + 0.5, 0])
            circle(d=1);
        }
        
        // Entry slot (pole slides in from front)
        translate([0, pole_max_dia/2 + clip_thick, 0])
        cube([clip_width + 2, pole_max_dia + 10, outer_h*0.7], center=true);
    }
}

// ══════════════════════════════════════════════════════════════
// Utility: rounded cube
// ══════════════════════════════════════════════════════════════

module rounded_cube(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=20);
        }
    }
}