Starting Repo and Project

hardware/3D_Print-Designs/FireFly3DMechanical_v0.1.scad

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+/*
+    FireFly tetrahedron adapter
+    Base STL: tetrahedron40mmC.stl
+
+    Purpose:
+    - Import original 40 mm foldable tetrahedron STL
+    - Scale it to 60 mm base geometry
+    - Add cable holes, vent/drain holes, and optional PCB mounting holes
+
+    Workflow:
+    1. Set PART = "upper"
+    2. Render with F6
+    3. Export STL
+    4. Set PART = "lower"
+    5. Render with F6
+    6. Export STL
+
+    Notes:
+    - Hole coordinates are defined on the original 40 mm STL coordinate system.
+    - The script scales them automatically to 60 mm.
+    - First export should be treated as v0.1 prototype.
+*/
+
+
+/* =========================
+   Main selection
+   ========================= */
+
+PART = "upper";          // "upper", "lower", or "both_preview"
+
+
+/* =========================
+   Input file
+   ========================= */
+
+input_stl = "tetrahedron40mmC.stl";
+
+
+/* =========================
+   Scaling
+   ========================= */
+
+// Original tetrahedron edge length
+original_edge_mm = 40;
+
+// Target mechanical base size
+target_edge_mm = 60;
+
+// XY scale from 40 mm to 60 mm
+scale_xy = target_edge_mm / original_edge_mm;   // 1.5
+
+// Keep original thickness.
+// Set to 1.2 or 1.3 if you want a slightly thicker part.
+scale_z = 1.0;
+
+
+/* =========================
+   General hole settings
+   ========================= */
+
+hole_fn = 40;
+cut_height = 20;
+
+
+/* =========================
+   Feature switches
+   ========================= */
+
+add_upper_cable_holes = true;
+add_upper_hanger_hole = true;
+
+add_lower_vent_holes = true;
+add_lower_cable_holes = true;
+add_lower_pcb_mount_holes = true;
+
+// Keep this false for the first prototype.
+// Standoffs may interfere with folding depending on print orientation.
+add_lower_pcb_standoffs = false;
+
+
+/* =========================
+   Hole sizes
+   ========================= */
+
+cable_hole_d = 3.2;          // for small solar-panel wires
+hanger_hole_d = 3.5;         // for small ring / wire / eyelet
+vent_hole_d = 2.0;           // condensation vent / drain holes
+pcb_screw_hole_d = 2.2;      // M2 clearance-ish
+pcb_standoff_d = 6.0;
+pcb_standoff_h = 3.0;
+
+
+/* =========================
+   Coordinate reference
+   =========================
+
+   The uploaded STL is approximately:
+
+   X: -34.64 to +34.64
+   Y: -20.00 to +60.00
+   Z:  -0.10 to  +2.00
+
+   The original model is a flat foldable tetrahedron net.
+   Coordinates below are before scaling.
+*/
+
+
+/* =========================
+   Upper part hole positions
+   ========================= */
+
+// Cable holes for three solar panels.
+// Adjust after checking where your real panel wires exit.
+upper_cable_points = [
+    [-18, 20],
+    [ 24,  7],
+    [ 24, 33]
+];
+
+// Optional hanger hole close to one upper fold/vertex area.
+// If this weakens the corner too much, disable it and use an external loop instead.
+upper_hanger_points = [
+    [0, 38]
+];
+
+
+/* =========================
+   Lower part hole positions
+   ========================= */
+
+// Cable transfer holes between upper solar section and lower electronics bay.
+lower_cable_points = [
+    [-10, 20],
+    [ 12, 13],
+    [ 12, 27]
+];
+
+// Small vent/drain hole clusters near likely lower/edge areas.
+// These are deliberately small.
+lower_vent_centres = [
+    [  0,  3],
+    [  0, 37],
+    [-30, 20],
+    [ 31, 20]
+];
+
+// Approximate triangular PCB mounting pattern.
+// Tune this after measuring your actual red triangle PCB.
+lower_pcb_mount_points = [
+    [  0,  8],
+    [ 25, 20],
+    [  0, 32]
+];
+
+
+/* =========================
+   Basic modules
+   ========================= */
+
+module base_import_scaled()
+{
+    scale([scale_xy, scale_xy, scale_z])
+        import(input_stl, convexity = 10);
+}
+
+
+module vertical_hole(p, d)
+{
+    translate([p[0] * scale_xy, p[1] * scale_xy, 1])
+        cylinder(h = cut_height, d = d, center = true, $fn = hole_fn);
+}
+
+
+module vent_cluster(p)
+{
+    // Small 2 x 3 vent/drain pattern.
+    // Pitch is in final millimetres, not original model coordinates.
+    pitch = 3.0;
+
+    for (ix = [-1, 0, 1])
+        for (iy = [0, 1])
+            translate([
+                p[0] * scale_xy + ix * pitch,
+                p[1] * scale_xy + iy * pitch,
+                1
+            ])
+                cylinder(h = cut_height, d = vent_hole_d, center = true, $fn = hole_fn);
+}
+
+
+module pcb_standoff(p)
+{
+    // Standoff added on top of the flat STL.
+    // Use only if you confirm it does not block folding.
+    translate([p[0] * scale_xy, p[1] * scale_xy, 2.1 * scale_z])
+        cylinder(h = pcb_standoff_h, d = pcb_standoff_d, center = false, $fn = hole_fn);
+}
+
+
+/* =========================
+   Upper tetrahedron
+   ========================= */
+
+module upper_part()
+{
+    difference()
+    {
+        base_import_scaled();
+
+        if (add_upper_cable_holes)
+        {
+            for (p = upper_cable_points)
+                vertical_hole(p, cable_hole_d);
+        }
+
+        if (add_upper_hanger_hole)
+        {
+            for (p = upper_hanger_points)
+                vertical_hole(p, hanger_hole_d);
+        }
+    }
+}
+
+
+/* =========================
+   Lower tetrahedron
+   ========================= */
+
+module lower_part()
+{
+    difference()
+    {
+        union()
+        {
+            base_import_scaled();
+
+            if (add_lower_pcb_standoffs)
+            {
+                for (p = lower_pcb_mount_points)
+                    pcb_standoff(p);
+            }
+        }
+
+        if (add_lower_cable_holes)
+        {
+            for (p = lower_cable_points)
+                vertical_hole(p, cable_hole_d);
+        }
+
+        if (add_lower_vent_holes)
+        {
+            for (p = lower_vent_centres)
+                vent_cluster(p);
+        }
+
+        if (add_lower_pcb_mount_holes)
+        {
+            for (p = lower_pcb_mount_points)
+                vertical_hole(p, pcb_screw_hole_d);
+        }
+    }
+}
+
+
+/* =========================
+   Output
+   ========================= */
+
+if (PART == "upper")
+{
+    upper_part();
+}
+else if (PART == "lower")
+{
+    lower_part();
+}
+else if (PART == "both_preview")
+{
+    translate([-80, 0, 0])
+        upper_part();
+
+    translate([80, 0, 0])
+        lower_part();
+}
+else
+{
+    echo("Invalid PART setting. Use upper, lower, or both_preview.");
+}