// RemoteRig — Dual-ESP Tripod Case v3
// v3d changes: screw-tightened tripod clamp + horizontal two-screw mount + flush locating-lip lid.
// 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;

// Lid fit parameters
lid_top_thick = 2.0;
lid_lip_h     = 1.6;
lid_clearance = 0.6;   // clearance around underside locating lip
lid_lip_wall  = 1.2;   // thickness of perimeter lip/frame

// 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

// Case ↔ clamp interface
// v3b removes the dovetail: use a flat two-screw mounting plate instead.
// This is simpler to print, easier to inspect, and field-serviceable.
mount_plate_w      = 24.0;
mount_plate_h      = 16.0;
mount_plate_thick  = 4.0;
mount_hole_spacing = 14.0;  // side-by-side M3 case-mount screws
mount_screw_clear  = 3.4;   // M3 clearance through clamp plate
mount_case_pilot   = 2.7;   // pilot/insert hole through case boss
mount_boss_r       = 1.2;

// 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 case_mount_boss() {
    // Flat rear boss on the case. The clamp plate bolts directly to this face.
    // Holes run front/back (Y axis) for M3 screws, heat-set inserts, or nuts.
    boss_y = outer_d/2 + mount_plate_thick/2 - 0.2;
    difference() {
        translate([0, boss_y, outer_h/2])
            rounded_cube_centered(mount_plate_w, mount_plate_thick, mount_plate_h, mount_boss_r);

        for (xoff = [-mount_hole_spacing/2, mount_hole_spacing/2]) {
            translate([xoff, outer_d/2 + mount_plate_thick/2, outer_h/2])
                rotate([90, 0, 0])
                    cylinder(d=mount_case_pilot, h=mount_plate_thick + wall*3, center=true, $fn=24);
        }
    }
}

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));
        case_mount_boss();
    }
}

module lid_locating_lip() {
    // Thin underside frame that drops into the case opening. This registers the
    // lid so it cannot skate/rock on the rim, while staying clear of screw posts.
    lip_outer_w = inner_w + tol - lid_clearance;
    lip_outer_d = inner_d + tol - lid_clearance;
    lip_inner_w = lip_outer_w - lid_lip_wall*2;
    lip_inner_d = lip_outer_d - lid_lip_wall*2;

    translate([0, 0, -lid_lip_h])
        difference() {
            rounded_cube0(lip_outer_w, lip_outer_d, lid_lip_h, 1.0);
            translate([0, 0, -0.1])
                rounded_cube0(lip_inner_w, lip_inner_d, lid_lip_h + 0.2, 0.7);

            // Corner reliefs so the lip doesn't interfere with screw posts.
            for (x = [-1, 1], y = [-1, 1]) {
                translate([x*(outer_w/2 - 5), y*(outer_d/2 - 5), lid_lip_h/2])
                    cylinder(d=7.0, h=lid_lip_h + 0.4, center=true, $fn=24);
            }
        }
}

module case_lid() {
    difference() {
        union() {
            // Thinner top cover; underside lip handles registration.
            rounded_cube0(outer_w, outer_d, lid_top_thick, 0.8);
            lid_locating_lip();
        }

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

        for (x = [-outer_w/4, 0, outer_w/4]) {
            translate([x, 0, lid_top_thick/2])
                cube([8, outer_d*0.6, lid_top_thick*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 + tol, 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 clamp_mount_plate() {
    outer_r = pole_dia/2 + clamp_thick;
    plate_y = -outer_r - mount_plate_thick/2 + 0.2;

    // Flat plate matching the case boss. Two M3 clearance holes pass through
    // along Y so the clamp bolts to the case with ordinary hardware.
    difference() {
        translate([0, plate_y, 0])
            rounded_cube_centered(mount_plate_w, mount_plate_thick, mount_plate_h, mount_boss_r);

        for (xoff = [-mount_hole_spacing/2, mount_hole_spacing/2]) {
            translate([xoff, plate_y, 0])
                rotate([90, 0, 0])
                    cylinder(d=mount_screw_clear, h=mount_plate_thick + 2, center=true, $fn=24);
        }
    }
}

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

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

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