merge main

Author: gluap

export/MainCase/UsbCover.stl

@@ -5,34 +5,35 @@ $fn = 64;
 depth = UsbCover_depth+UsbCover_foot_length;
 
 
-module 2DBase(inset=0) {
+module 2DBase(inset=0, clearance=0) {
     // inset is required for chamfer
     UsbCover_r1=UsbCover_r1-inset;
     UsbCover_r2=UsbCover_r2-inset;
     rMax=max(UsbCover_r1,UsbCover_r2);
 
     // one side of the rounded rectangle
+    translate([clearance, 0, 0])
     difference(){
-      offset(r=UsbCover_r1) square([depth-UsbCover_r1*2-inset*2,UsbCover_width-UsbCover_r1*2-inset*2],center=true);
-      translate([depth/4 + rMax/2,0])square([depth/2+rMax,UsbCover_width+rMax], center=true);
+      offset(r=UsbCover_r1) square([depth-UsbCover_r1*2-inset*2,UsbCover_width-UsbCover_r1*2-inset*2-2*clearance],center=true);
+      translate([depth/4 + rMax/2,0])square([depth/2+rMax,UsbCover_width+rMax-clearance], center=true);
     }
     // other side - slightly different radius
     difference(){
-      offset(r=UsbCover_r2) square([depth-UsbCover_r2*2-inset*2,UsbCover_width-UsbCover_r2*2-inset*2],center=true);
-      translate([-(depth/4 + rMax/2),0])square([depth/2+rMax,UsbCover_width+rMax], center=true);
+      offset(r=UsbCover_r2) square([depth-UsbCover_r2*2-inset*2,UsbCover_width-UsbCover_r2*2-inset*2-2*clearance],center=true);
+      translate([-(depth/4 + rMax/2),0])square([depth/2+rMax,UsbCover_width+rMax-clearance], center=true);
     }
 }
 
-module 2DRail(inset=0)
+module 2DRail(inset=0, clearance=0)
 {
     // only the side rail
-    translate([-depth/2+UsbCover_wing_width/2+UsbCover_wing_offset,0,0])square([UsbCover_wing_width-inset*2,UsbCover_width+2*UsbCover_wing_length-inset*2],center=true);
+    translate([-depth/2+UsbCover_wing_width/2+UsbCover_wing_offset,0,0])square([UsbCover_wing_width-inset*2-clearance,UsbCover_width+2*(UsbCover_wing_length-clearance)-inset*2],center=true);
 }
 
-module 2DTop(inset=0) {
+module 2DTop(inset=0, clearance=0) {
     // the top shape is the bottom shape with a cutoff at the edge
     difference() {
-        2DBase(inset=inset);
+        2DBase(inset=inset, clearance=clearance);
         translate([7.4,0])square([depth+UsbCover_r1,UsbCover_width+UsbCover_r1],center=true);
     }
 }
@@ -42,6 +43,8 @@ module UsbCoverMainBody(chamfer=0.5, clearance=0, counter_magnets=false) {
     // translation into world coordinates
 
     if (clearance > 0) {
+        // Positive clearance is used in the cutout of the MainCase.
+        
         // clearance by minkowski with cylinder
         minkowski(){
             UsbCoverMainBody(chamfer=0,clearance=0);
@@ -52,26 +55,30 @@ module UsbCoverMainBody(chamfer=0.5, clearance=0, counter_magnets=false) {
         }
 
     } else {
+        // Negative clearance is used in the correction of the actual UsbCover
+        // part for printing smaller items to fit existing cases with not
+        // enough actual clearance.
+
         rotate([0,0,90])translate([depth/2,0,0]) {
             //rail with chamfer top and bottom
             hull() {
-                linear_extrude(0.01){2DRail(inset=chamfer);}
-                translate([0,0,chamfer])linear_extrude(epsilon){2DRail(inset=0);}
-                translate([0,0,UsbCover_height-chamfer-epsilon])linear_extrude(epsilon){2DRail(inset=0);}
-                translate([0,0,UsbCover_height-epsilon])linear_extrude(epsilon){2DRail(inset=chamfer);}
+                linear_extrude(0.01){2DRail(inset=chamfer,clearance=-clearance);}
+                translate([0,0,chamfer])linear_extrude(epsilon){2DRail(inset=0,clearance=-clearance);}
+                translate([0,0,UsbCover_height-chamfer-epsilon])linear_extrude(epsilon){2DRail(inset=0,clearance=-clearance);}
+                translate([0,0,UsbCover_height-epsilon])linear_extrude(epsilon){2DRail(inset=chamfer,clearance=-clearance);}
             }
             // bottom with chamfer up to grip
             hull()
             {
-                linear_extrude(0.01){2DBase(inset=chamfer);}
-                translate([0,0,chamfer])linear_extrude(epsilon){2DBase(inset=0);}
-                translate([0,0,UsbCover_foot_height-epsilon])linear_extrude(epsilon){2DBase(inset=0);}
+                linear_extrude(0.01){2DBase(inset=chamfer,clearance=-clearance);}
+                translate([0,0,chamfer])linear_extrude(epsilon){2DBase(inset=0,clearance=-clearance);}
+                translate([0,0,UsbCover_foot_height-epsilon])linear_extrude(epsilon){2DBase(inset=0,clearance=-clearance);}
             }
             // top with chamfer
             hull(){
-                translate([0,0,UsbCover_foot_height])linear_extrude(epsilon){2DTop(inset=0);}
-                translate([0,0,UsbCover_height-chamfer-epsilon])linear_extrude(epsilon){2DTop(inset=0);}
-                translate([0,0,UsbCover_height-epsilon])linear_extrude(epsilon){2DTop(inset=chamfer);}
+                translate([0,0,UsbCover_foot_height])linear_extrude(epsilon){2DTop(inset=0,clearance=-clearance);}
+                translate([0,0,UsbCover_height-chamfer-epsilon])linear_extrude(epsilon){2DTop(inset=0,clearance=-clearance);}
+                translate([0,0,UsbCover_height-epsilon])linear_extrude(epsilon){2DTop(inset=chamfer,clearance=-clearance);}
             }
             //top chamfers are moved down by slice thickness
         }
@@ -124,7 +131,7 @@ module 3DGripMould(){
 
 module UsbCover(chamfer=0.5){
     difference(){
-        UsbCoverMainBody(chamfer=chamfer);
+        UsbCoverMainBody(chamfer=chamfer, clearance=-UsbCover_clearance_correction);
         3DGripMould();
         MagnetHoles();
     }

export/Mounting/SeatPostMount.stl

@@ -96,6 +96,7 @@ UsbCover_indent_width = 12;
 UsbCover_wing_offset = 2.2;
 UsbCover_wing_width = 2.6;
 UsbCover_wing_length = 2.0;
+UsbCover_clearance_correction = default_clearance; // printing a smaller-than-spec part for main cases that have not enough clearance themselves
 
 MainCase_small_corner_radius = 5;
 MainCase_switch_offset_x = 25;