additional mechanical parts for housing

firmware/ATTINY85_2026_MorseThrowie/ATTINY85_2026_MorseThrowie.ino

@@ -0,0 +1,544 @@
+/*
+ =============================================================================
+ FireFly Morse Throwie 
+ - a light controled (LED as Sensor) morseblinker throwie with ATTiny45/85
+ ============================================================================= 
+ 
+ Project definitions, sources
+ ----------------------------------------------------------------------------- 
+ Version: 0.1 - Attiny85 Version
+ Date   : 25.05.2026
+
+ -----------------------------------------------------------------------------
+
+ Inspired by Karl Lunt's FireFly project I wrote some code to make this
+   Throwie lasting longer, blinking only at low light levels and morse also
+   some text.
+   http://www.seanet.com/~karllunt/fireflyLED.html
+
+ How it works (only the Morsethrowy part):
+   LED detects light level, using bleeding out time of LED pn-capacitor.
+   If dark enough blink a text in morsecode (ATTiny45 = 22 Chars, text will 
+   be defined in line 191/192 of this file)
+   To save energy go to powersave mode after blinking or light level is
+   over threshold. Tests this every 8s (maximum time for watchdog timer 
+   possible for ATTiny). Repeat this endless
+   
+ 
+     The wiring, it's very simple, see also HW part of the Project.
+     
+                     +---+      +------\/------+
+                         |      | ATTINY45 /85 |
+                     >   |     -+1=PB5    VCC=8+-> to SuperCap / DC-DC 3V/5V
+             xxx Ohm <   |      |              |
+                     >   +------+2=PB3    PB2=7+-
+                     |          |              |
+                   ----- +------+3=PB4    PB1=6+-
+             LED    / \  |      |              |
+                   ----- |   +--+4=GND    PB0=5+-
+                     |   |   |  |              |
+                     +---+   |  +--------------+
+                             |
+                             +---------------------> to battery GND
+            
+  You can use other pins if necessary, theoretical up to 3 LEDs, as example I
+  tried out to connect another one at PB2&PB1. working fine. Basic wiring:
+ 
+          + LED_N_Side), wired to a digital pin, NOT Vcc
+          |
+          <
+          > 100 - 460 ohm resistor depending Voltage 
+          <
+          |
+          |
+        -----
+         / \  LED, maybe a 5mm, clear plastic is good
+        -----
+          |
+          |
+          + LED_P_Side), wired to a digital pin, NOT Gnd
+
+ -----------------------------------------------------------------------------
+ Im just a newbe in ATTiny / Arduino programming, so many thanks to:
+ 
+ Programming ATTiny with Arduino IDE:
+   http://highlowtech.org/?p=1695 
+ 
+ LED Lightsensor, Arduino Playground:
+   http://playground.arduino.cc/Learning/LEDSensor
+  
+ Powersaving Mode for Attiny45/85:
+   A good description by Martin Nawrath nawrath@khm.de and the folks at
+   http://www.insidegadgets.com/2011/02/05/reduce-attiny-power-consumption-by-sleeping-with-the-watchdog-timer/
+   
+   With this description I got ~5uA during sleep mode.
+   in Morse-Mode with LED OFF: 1.7mA 
+                      LED ON:  6.9mA
+   --> I hope to run this throwies ~40days with one CR2032.
+
+ Morsecode
+   To translate a text into morsecode, there are several ways. You can use
+   this fine online translator:
+   http://morsecode.scphillips.com/jtranslator.html
+ 
+   There is also a great morse coder / encoder from Matthias Esterl aka madc.
+   Works fine for Arduino, but not for ATTiny because of RAM limitations. But
+   maybe this is helpful if your project works with an Arduino.
+   https://gist.github.com/madc/4474559
+
+   For this project I use a simple case structur. Looks arkward, but the
+   ATTiny45 has only 256byte RAM but 4kFlash. A data structure is better programming
+   but needs a lot of RAM we not have. Therefore this ugly case structure.
+   This will waste the flash memory but we have enough and saving RAM for
+   our payload - the ASCII-string with the morsetext.
+ 
+ BTW - Morsecode itself:
+   
+     'A', ".-"      'B', "-..."    'C', "-.-."
+     'D', "-.."     'E', "."       'F', "..-."
+     'G', "--."     'H', "...."    'I', ".."
+     'J', ".---"    'K', ".-.-"    'L', ".-.."
+     'M', "--"      'N', "-."      'O', "---"
+     'P', ".--."    'Q', "--.-"    'R', ".-."
+     'S', "..."     'T', "-"       'U', "..-"
+     'V', "...-"    'W', ".--"     'X', "-..-"
+     'Y', "-.--"    'Z', "--.."    
+ 
+     '1', ".----"   '2', "..---"   '3', "...--"
+     '4', "....-"   '5', "....."   '6', "-...."
+     '7', "--..."   '8', "---.."   '9', "----."
+     '0', "-----"
+   
+     '.', ".-.-.-"  ',', "--..--" '?', "..--.."
+     '!', "-.-.--"  ':', "---..." ';', "-.-.-."
+     '(', "-.--."   ')', "-.--.-" '"', ".-..-."
+     '@', ".--.-."  '&', ".-..." 
+
+ -----------------------------------------------------------------------------
+ Legal stuff / Copyright: 
+   Creative Commons Attribution ShareAlike 3.0.:
+   http://creativecommons.org/licenses/by-sa/3.0/legalcode
+ -----------------------------------------------------------------------------
+*/
+
+
+// ===========================================================================
+// Ok folks, let's start
+// ===========================================================================
+// for sleep Mode / Powersave we need some additional stuff. Its alredy there,
+// if you installed the Attiny extension for Arduino IDE, no additional
+// installing needed.
+#include <avr/sleep.h>
+#include <avr/wdt.h>
+
+// ===========================================================================
+// Some definitions for powersave depending of ATTiny type.
+#ifndef cbi
+#define cbi(sfr, bit) (_SFR_BYTE(sfr) &= ~_BV(bit))
+#endif
+#ifndef sbi
+#define sbi(sfr, bit) (_SFR_BYTE(sfr) |= _BV(bit))
+#endif
+
+// ===========================================================================
+// for ATTiny85
+// Unit length < 150 will hard to be read for optical morse code
+//             > 300 are too slow in my feeling for longer text
+//
+// for ATTiny85 at 8MHz (for 1MHz see ATTiny45)
+// Unit length < 5   will hard to be read for optical morse code
+//             > 10  are too slow in my feeling for longer text
+//
+// 
+
+#define unitLength 100  
+
+// ---------------------------------------------------------------------------
+// LED Pin definitions, 
+// theoretical you can use up to 3 LED. For example you can use it for a
+// landmark beacon. So if you point this LEDs to different directions you can 
+// detect the position in dependence of your location to the bacon. 
+#define LED1_N_SIDE 3 
+#define LED1_P_SIDE 4
+
+// ===========================================================================
+// Variables
+// ===========================================================================
+// ###########################################################################
+// # and now the text, but be aware, only 256Byte RAM for Attiny45           #
+// # so there are only 22 Chars left for your message.                       #
+// # BTW with an Attiny85 you will have additional 256byte                   #
+// # => more than for twitter :-)                                            #
+// # => for FireFly with SuperCap: less ist better, charge last longer       #
+
+String morseText =
+     "TOGO LAB";
+// # "....5....1....5....2.."; just a ruler, remember 22 Chars for ATTiny #
+//    IT IS USELESS
+//    HAIL GLOW CLOUD
+// ###########################################################################
+
+// Define light trigger threshold. best way to set it on dusk / dawn level
+// diffuse red ones are less sensitive than clear green ones...
+int darknessThreshold = 17000;
+
+// Interrupt Flag, should be volatile, means: read from RAM, not register
+// because registers are used for interrupt handling, it have to be volatile.
+volatile boolean f_wdt = 1;
+
+// ===========================================================================
+// Setup watchdog
+// 0=16ms, 1=32ms,2=64ms,3=128ms,4=250ms,5=500ms
+// 6=1 sec,7=2 sec, 8=4 sec, 9= 8sec
+// ===========================================================================
+void setup()
+{
+  setup_watchdog(9);
+}
+
+// ===========================================================================
+// Main
+// ===========================================================================
+
+void loop(){
+
+  if (f_wdt==1) {  // wait for timed out watchdog 
+                   // flag is set when a watchdog timeout occurs
+    f_wdt=0;       // reset flag  
+  
+    // if it's dark enough [>darknesThreshold] morse
+    if (sensDarkness(LED1_N_SIDE, LED1_P_SIDE) > darknessThreshold){
+      // looks like it's dark, so do your job
+      morse(LED1_N_SIDE, LED1_P_SIDE); 
+    }
+  }
+  // set all used port to intput to save power
+  pinMode(LED1_N_SIDE,INPUT);
+  pinMode(LED1_P_SIDE,INPUT);
+  system_sleep();
+  f_wdt=0;          // 2nd time sleep
+  system_sleep();
+}
+
+// ===========================================================================
+// Subroutines for Sleeping
+// ===========================================================================
+// set system into the sleep state 
+// system wakes up when wtchdog is timed out
+void system_sleep() {
+  cbi(ADCSRA,ADEN);                    // switch Analog to 
+                                       // Digitalconverter OFF
+
+  set_sleep_mode(SLEEP_MODE_PWR_DOWN); // sleep mode is set here
+  sleep_enable();
+
+  sleep_mode();                        // System sleeps here
+
+  sleep_disable();                     // System continues execution here when
+                                       // watchdog timed out 
+  sbi(ADCSRA,ADEN);                    // switch Analog to Digitalconverter ON
+}
+
+// ----------------------------------------------------------------------------
+// Setup for watchdog. Parameter ii for sleeping time:
+//      0 =  16ms, 1 =  32ms, 2 =  64ms, 
+//      3 = 128ms, 4 = 250ms, 5 = 500ms
+//      6 = 1 sec, 7 = 2 sec, 8 = 4 sec,
+//      9 = 8 sec
+void setup_watchdog(int ii) {
+
+  byte bb;
+  int ww;
+  if (ii > 9 ) ii=9;
+  bb=ii & 7;
+  if (ii > 7) bb|= (1<<5);
+  bb|= (1<<WDCE);
+  ww=bb;
+
+  MCUSR &= ~(1<<WDRF);
+  
+  WDTCR |= (1<<WDCE) | (1<<WDE);       // start timed sequence
+
+  WDTCR = bb;                          // set new watchdog timeout value
+  WDTCR |= _BV(WDIE);
+}
+// -----------------------------------------------------------------------------
+// Watchdog Interrupt Service / is executed when watchdog timed out
+ISR(WDT_vect) {
+  f_wdt=1;                             // set global flag
+}
+
+// =============================================================================
+// Subroutines for light sensor
+// =============================================================================
+// Function sensDarkness
+// Usage: sensDarkness(Pin-No. N-Side of LED, Pin-No. P-Side of LED):
+// will result "darkness-level" - the higher the darker:
+//      30000 = pitch black
+//      0     = sunshine
+int sensDarkness(int LED_N, int LED_P){
+
+  unsigned int i;                        //Parameter bleed-out LED capacitor
+
+  // charge the capacitor of LED  
+  pinMode(LED_N,OUTPUT);
+  pinMode(LED_P,OUTPUT);
+  digitalWrite(LED_N,HIGH);
+  digitalWrite(LED_P,LOW);
+
+  // Isolate the N end of the diode and turn off internal pull-up resistor
+  pinMode(LED_N,INPUT);
+  digitalWrite(LED_N,LOW);
+
+  // Count how long it takes the diode to bleed back down to a logic zero
+  for ( i = 0; i < 30000; i++) {
+    if ( digitalRead(LED_N)==0) break;
+  }
+  // thats it, return result
+  return i;
+}
+
+// =============================================================================
+// Subroutines for morse text
+// =============================================================================
+// -----------------------------------------------------------------------------
+// Function dit = ".", a dit is as long as a unitLength, used in morse()
+//
+void dit(int LED_P){
+  digitalWrite( LED_P, HIGH ); delay( unitLength );
+  digitalWrite( LED_P, LOW );  delay( unitLength );
+}  
+
+// -----------------------------------------------------------------------------
+// Function dah = "-", a dah is as long as a 3*unitLength
+//
+void dah(int LED_P){
+  digitalWrite( LED_P, HIGH ); delay( unitLength*3 );
+  digitalWrite( LED_P, LOW );  delay( unitLength );
+}  
+
+// -----------------------------------------------------------------------------
+// Function morse:
+//   hand over text and LED Pins
+//   because you want to use more than one LED hand over also LED Pins
+
+void morse(int LED_N, int LED_P){
+  
+  // Because I have more Flash than RAM I decided to use a case structure.
+  // Its not so pretty, but I can use the RAM to hold my morseText.
+  //
+  // set N-Side of LED Low, so you can set P-side high to let them flash
+
+  pinMode( LED_N, OUTPUT);
+  pinMode( LED_P, OUTPUT);
+
+  digitalWrite( LED_N, LOW);
+
+  // send it to defined LED
+  for(int i=0; i<=morseText.length(); i++)
+  {
+    switch( morseText[i] )
+    {            
+ 
+    // Chars A-Z
+    case 'A': // .-
+      dit(LED_P); dah(LED_P);
+      break;
+ 
+    case 'B': // -...
+      dah(LED_P); dit(LED_P); dit(LED_P); dit(LED_P);
+      break;
+
+    case 'C': // -.-.
+      dah(LED_P); dit(LED_P); dah(LED_P); dit(LED_P); 
+      break;
+
+    case 'D': // -..
+      dah(LED_P); dit(LED_P); dit(LED_P); 
+      break; 
+
+    case 'E': // .
+      dit(LED_P);
+      break; 
+
+    case 'F': // ..-.
+      dit(LED_P); dit(LED_P); dah(LED_P); dit(LED_P);
+      break; 
+
+    case 'G': // --.
+      dah(LED_P); dah(LED_P); dit(LED_P); 
+      break; 
+
+    case 'H': // ....
+      dit(LED_P); dit(LED_P); dit(LED_P); dit(LED_P);
+      break; 
+
+    case 'I': // ..
+      dit(LED_P); dit(LED_P);
+      break; 
+
+    case 'J': // .---
+      dit(LED_P); dah(LED_P); dah(LED_P); dah(LED_P);
+      break; 
+
+    case 'K': // .-.-
+      dit(LED_P); dah(LED_P); dit(LED_P); dah(LED_P);
+      break; 
+
+    case 'L': // .-..
+      dit(LED_P); dah(LED_P); dit(LED_P); dit(LED_P);
+      break; 
+
+    case 'M': // --
+       dah(LED_P); dah(LED_P);
+      break; 
+
+    case 'N': // -.
+      dah(LED_P); dit(LED_P);
+      break; 
+
+    case 'O': // ---
+      dah(LED_P); dah(LED_P); dah(LED_P);
+      break; 
+
+    case 'P': // .--.
+      dit(LED_P); dah(LED_P); dah(LED_P); dit(LED_P);
+      break; 
+
+    case 'Q': // --.-
+      dah(LED_P); dah(LED_P); dit(LED_P); dah(LED_P); 
+      break; 
+
+    case 'R': // .-.
+      dit(LED_P); dah(LED_P); dit(LED_P);
+      break; 
+      
+    case 'S': // ...
+      dit(LED_P); dit(LED_P); dit(LED_P);
+      break;       
+
+    case 'T': // -
+      dah(LED_P);
+      break; 
+
+    case 'U': // ..-
+      dit(LED_P); dit(LED_P); dah(LED_P);
+      break; 
+
+    case 'V': // ...-
+      dit(LED_P); dit(LED_P); dit(LED_P); dah(LED_P);
+      break; 
+
+    case 'W': // .--
+      dit(LED_P); dah(LED_P); dah(LED_P);
+      break; 
+
+    case 'X': // -..-
+       dah(LED_P); dit(LED_P); dit(LED_P); dah(LED_P);
+      break; 
+
+    case 'Y': // -.--
+       dah(LED_P); dit(LED_P); dah(LED_P); dah(LED_P);
+      break; 
+
+    case 'Z': // --..
+      dah(LED_P);dah(LED_P); dit(LED_P); dit(LED_P);
+      break; 
+
+    // Numbers
+    case '1': // .----
+      dit(LED_P); dah(LED_P); dah(LED_P); dah(LED_P); dah(LED_P);
+      break; 
+
+    case '2': // ..---
+      dit(LED_P); dit(LED_P); dah(LED_P); dah(LED_P); dah(LED_P);
+      break; 
+
+    case '3': // ...--
+      dit(LED_P); dit(LED_P); dit(LED_P); dah(LED_P); dah(LED_P);
+      break; 
+
+    case '4': // ....-
+      dit(LED_P); dit(LED_P); dit(LED_P); dit(LED_P); dah(LED_P);
+      break; 
+
+    case '5': // .....
+      dit(LED_P); dit(LED_P); dit(LED_P); dit(LED_P); dit(LED_P);
+      break; 
+
+    case '6': // -....
+      dah(LED_P); dit(LED_P); dit(LED_P); dit(LED_P); dit(LED_P); 
+      break; 
+
+    case '7': // --...
+      dah(LED_P); dah(LED_P); dit(LED_P); dit(LED_P); dit(LED_P); 
+      break; 
+
+    case '8': // ---..
+      dah(LED_P); dah(LED_P); dah(LED_P); dit(LED_P); dit(LED_P); 
+      break; 
+
+    case '9': // ----.
+      dah(LED_P); dah(LED_P); dah(LED_P); dah(LED_P); dit(LED_P); 
+      break; 
+
+    case '0': // -----
+      dah(LED_P); dah(LED_P); dah(LED_P); dah(LED_P); dah(LED_P); 
+      break; 
+
+    // Special Signs
+    case ' ': // Gap
+        delay( unitLength*5 );
+      break; 
+
+    case '.': // .-.-.-
+      dit(LED_P); dah(LED_P); dit(LED_P); dah(LED_P); dit(LED_P); dah(LED_P);
+      break; 
+
+    case ',': // --..--
+      dah(LED_P); dah(LED_P); dit(LED_P); dit(LED_P); dah(LED_P); dah(LED_P);
+      break; 
+
+    case '?': // ..--..
+      dit(LED_P); dit(LED_P); dah(LED_P); dah(LED_P); dit(LED_P); dit(LED_P);
+      break; 
+
+    case '!': // -.-.--
+      dah(LED_P); dit(LED_P); dah(LED_P); dit(LED_P); dah(LED_P); dah(LED_P);
+      break; 
+
+    case ':': // ---...
+      dah(LED_P); dah(LED_P); dah(LED_P); dit(LED_P); dit(LED_P); dit(LED_P);
+      break; 
+
+    case ';': // -.-.-.
+      dah(LED_P); dit(LED_P); dah(LED_P); dit(LED_P); dah(LED_P); dit(LED_P);
+      break; 
+
+    case '(': // -.--.
+      dah(LED_P); dit(LED_P); dah(LED_P); dah(LED_P); dit(LED_P);
+      break; 
+
+    case ')': // -.--.-
+      dah(LED_P); dit(LED_P); dah(LED_P); dah(LED_P); dit(LED_P); dah(LED_P);
+      break; 
+
+    case '"': // .-..-.
+      dit(LED_P); dah(LED_P); dit(LED_P); dit(LED_P); dah(LED_P); dit(LED_P);
+      break; 
+
+    case '@': // .--.-.
+      dit(LED_P); dah(LED_P); dah(LED_P); dit(LED_P); dah(LED_P); dit(LED_P);
+      break; 
+
+    case '&': // .-...
+      dit(LED_P); dah(LED_P); dit(LED_P); dit(LED_P); dit(LED_P);
+    }  
+    // wait at end of sign 
+    delay( unitLength*3 );
+  }
+}
+
+// -----------------------------------------------------------------------------
+// That's all, folks :-)
+// -----------------------------------------------------------------------------

firmware/archive/ATTINY45_2014_MorseThrowie/ATTINY45_2014_MorseThrowie.ino

@@ -183,8 +183,8 @@
 // theoretical you can use up to 3 LED. For example you can use it for a
 // landmark beacon. So if you point this LEDs to different directions you can 
 // detect the position in dependence of your location to the bacon. 
-#define LED1_N_SIDE 4
-#define LED1_P_SIDE 3
+#define LED1_N_SIDE 3 
+#define LED1_P_SIDE 4
 
 // ===========================================================================
 // Variables

hardware/0001_FireFly-Solar/0001_FireFly-Solar.kicad_dru

@@ -0,0 +1,5 @@
+(version 1)
+(rule Minimum_text_height_and_thickness_1
+	(constraint text_height (min 0.6mm))
+	(constraint text_thickness (min 0.1mm))
+)

hardware/0001_FireFly-Solar/0001_FireFly-Solar.kicad_prl

@@ -1,6 +1,6 @@
 {
   "board": {
-    "active_layer": 25,
+    "active_layer": 5,
     "active_layer_preset": "",
     "auto_track_width": true,
     "hidden_netclasses": [],

hardware/0001_FireFly-Solar/0001_FireFly-Solar.kicad_pro

@@ -1,6 +1,349 @@
 {
   "board": {
     "3dviewports": [],
+    "design_settings": {
+      "defaults": {
+        "apply_defaults_to_fp_barcodes": false,
+        "apply_defaults_to_fp_dimensions": false,
+        "apply_defaults_to_fp_fields": false,
+        "apply_defaults_to_fp_shapes": false,
+        "apply_defaults_to_fp_text": false,
+        "board_outline_line_width": 0.05,
+        "copper_line_width": 0.2,
+        "copper_text_italic": false,
+        "copper_text_size_h": 1.5,
+        "copper_text_size_v": 1.5,
+        "copper_text_thickness": 0.3,
+        "copper_text_upright": false,
+        "courtyard_line_width": 0.05,
+        "dimension_precision": 4,
+        "dimension_units": 3,
+        "dimensions": {
+          "arrow_length": 1270000,
+          "extension_offset": 500000,
+          "keep_text_aligned": true,
+          "suppress_zeroes": true,
+          "text_position": 0,
+          "units_format": 0
+        },
+        "fab_line_width": 0.1,
+        "fab_text_italic": false,
+        "fab_text_size_h": 1.0,
+        "fab_text_size_v": 1.0,
+        "fab_text_thickness": 0.15,
+        "fab_text_upright": false,
+        "other_line_width": 0.1,
+        "other_text_italic": false,
+        "other_text_size_h": 1.0,
+        "other_text_size_v": 1.0,
+        "other_text_thickness": 0.15,
+        "other_text_upright": false,
+        "pads": {
+          "drill": 0.7,
+          "height": 1.4,
+          "width": 1.4
+        },
+        "silk_line_width": 0.1,
+        "silk_text_italic": false,
+        "silk_text_size_h": 1.0,
+        "silk_text_size_v": 1.0,
+        "silk_text_thickness": 0.1,
+        "silk_text_upright": false,
+        "zones": {
+          "border_display_style": 2,
+          "border_hatch_pitch": 0.5,
+          "corner_radius": 0.0,
+          "corner_smoothing": 0,
+          "fill_mode": 0,
+          "hatch_gap": 1.5,
+          "hatch_orientation": 0.0,
+          "hatch_smoothing_level": 0,
+          "hatch_smoothing_value": 0.1,
+          "hatch_thickness": 1.0,
+          "min_clearance": 0.5,
+          "min_island_area": 10.0,
+          "min_thickness": 0.25,
+          "pad_connection": 1,
+          "remove_islands": 0,
+          "thermal_relief_gap": 0.5,
+          "thermal_relief_spoke_width": 0.5
+        }
+      },
+      "diff_pair_dimensions": [
+        {
+          "gap": 0.0,
+          "via_gap": 0.0,
+          "width": 0.0
+        }
+      ],
+      "drc_exclusions": [
+        [
+          "copper_edge_clearance|131952996|49276030|d5a8d279-1277-4128-8111-479753d97832|74ba0eb0-a42b-49db-8990-e7e337244d89",
+          ""
+        ],
+        [
+          "copper_edge_clearance|135254996|49276021|d5a8d279-1277-4128-8111-479753d97832|6760cf2b-9d51-44e9-8541-9b08cc6bed3a",
+          ""
+        ],
+        [
+          "copper_edge_clearance|138556996|49276011|d5a8d279-1277-4128-8111-479753d97832|5b16be99-1a09-4cc0-a4d6-0e5fae921e96",
+          ""
+        ],
+        [
+          "text_height|141224000|109999000|18cc7c24-1e1e-47b4-bd81-2abaec8c3831|00000000-0000-0000-0000-000000000000",
+          ""
+        ],
+        [
+          "text_thickness|129032000|119126000|be078bc2-b3be-4c33-abfe-930461332b78|00000000-0000-0000-0000-000000000000",
+          ""
+        ],
+        [
+          "text_thickness|129032000|122936000|57275588-b94d-44a7-b263-ab2e942abbb9|00000000-0000-0000-0000-000000000000",
+          ""
+        ],
+        [
+          "text_thickness|129032000|126746000|ac73bb6c-6b4c-4683-bc6b-c539afa6834f|00000000-0000-0000-0000-000000000000",
+          ""
+        ],
+        [
+          "text_thickness|129032000|130556000|dfc1c2d5-221c-45bf-8f4f-92d8a3ddf04a|00000000-0000-0000-0000-000000000000",
+          ""
+        ],
+        [
+          "text_thickness|129032000|134366000|e9026731-8c2e-491a-9b73-4cda2fa80a02|00000000-0000-0000-0000-000000000000",
+          ""
+        ],
+        [
+          "text_thickness|129032000|138176000|cf4eeb69-e06f-463f-be45-22626ac2c2b4|00000000-0000-0000-0000-000000000000",
+          ""
+        ],
+        [
+          "text_thickness|129032000|141986000|c29774df-bdb9-44e2-a17d-cfa3cd693d71|00000000-0000-0000-0000-000000000000",
+          ""
+        ],
+        [
+          "text_thickness|129184400|150241000|88401ad0-1dea-4344-ab33-329fd06bd493|00000000-0000-0000-0000-000000000000",
+          ""
+        ],
+        [
+          "text_thickness|135148000|106152000|7c4ccd6a-1b52-4734-bd95-092ada163852|00000000-0000-0000-0000-000000000000",
+          ""
+        ],
+        [
+          "text_thickness|135382000|84709000|88b0a397-e4a2-4145-86f6-0fa60b4a4bd9|00000000-0000-0000-0000-000000000000",
+          ""
+        ],
+        [
+          "text_thickness|141224000|109999000|18cc7c24-1e1e-47b4-bd81-2abaec8c3831|00000000-0000-0000-0000-000000000000",
+          ""
+        ],
+        [
+          "text_thickness|141325600|150144800|5da7a07f-f063-43b3-a149-e672965b459b|00000000-0000-0000-0000-000000000000",
+          ""
+        ],
+        [
+          "text_thickness|141478000|119126000|40b0fefb-8b86-43f7-b24d-e20c4677b223|00000000-0000-0000-0000-000000000000",
+          ""
+        ],
+        [
+          "text_thickness|141478000|122936000|77ee43fb-9700-42ab-8702-560042b5edd3|00000000-0000-0000-0000-000000000000",
+          ""
+        ],
+        [
+          "text_thickness|141478000|126746000|833d2a60-9010-4cb2-8045-b8050c8ee771|00000000-0000-0000-0000-000000000000",
+          ""
+        ],
+        [
+          "text_thickness|141478000|130556000|5a756363-e24d-4c12-82cf-59fc84a986ae|00000000-0000-0000-0000-000000000000",
+          ""
+        ],
+        [
+          "text_thickness|141478000|134366000|685c5797-de13-4bd0-a3b9-5fb75b4b9dad|00000000-0000-0000-0000-000000000000",
+          ""
+        ],
+        [
+          "text_thickness|141478000|138176000|15931c23-e5f6-4be3-ba3e-7a720c730e9b|00000000-0000-0000-0000-000000000000",
+          ""
+        ],
+        [
+          "text_thickness|141478000|141986000|e240b788-8dbb-43c9-8c9f-717e069201be|00000000-0000-0000-0000-000000000000",
+          ""
+        ]
+      ],
+      "meta": {
+        "version": 2
+      },
+      "rule_severities": {
+        "annular_width": "error",
+        "clearance": "error",
+        "connection_width": "warning",
+        "copper_edge_clearance": "error",
+        "copper_sliver": "warning",
+        "courtyards_overlap": "error",
+        "creepage": "error",
+        "diff_pair_gap_out_of_range": "error",
+        "diff_pair_uncoupled_length_too_long": "error",
+        "drill_out_of_range": "error",
+        "duplicate_footprints": "warning",
+        "extra_footprint": "warning",
+        "footprint": "error",
+        "footprint_filters_mismatch": "ignore",
+        "footprint_symbol_field_mismatch": "warning",
+        "footprint_symbol_mismatch": "warning",
+        "footprint_type_mismatch": "ignore",
+        "hole_clearance": "error",
+        "hole_to_hole": "warning",
+        "holes_co_located": "warning",
+        "invalid_outline": "error",
+        "isolated_copper": "warning",
+        "item_on_disabled_layer": "error",
+        "items_not_allowed": "error",
+        "length_out_of_range": "error",
+        "lib_footprint_issues": "warning",
+        "lib_footprint_mismatch": "warning",
+        "malformed_courtyard": "error",
+        "microvia_drill_out_of_range": "error",
+        "mirrored_text_on_front_layer": "warning",
+        "missing_courtyard": "ignore",
+        "missing_footprint": "warning",
+        "missing_tuning_profile": "warning",
+        "net_conflict": "warning",
+        "nonmirrored_text_on_back_layer": "warning",
+        "npth_inside_courtyard": "error",
+        "padstack": "warning",
+        "pth_inside_courtyard": "error",
+        "shorting_items": "error",
+        "silk_edge_clearance": "ignore",
+        "silk_over_copper": "warning",
+        "silk_overlap": "ignore",
+        "skew_out_of_range": "error",
+        "solder_mask_bridge": "error",
+        "starved_thermal": "ignore",
+        "text_height": "warning",
+        "text_on_edge_cuts": "error",
+        "text_thickness": "warning",
+        "through_hole_pad_without_hole": "error",
+        "too_many_vias": "error",
+        "track_angle": "error",
+        "track_dangling": "warning",
+        "track_not_centered_on_via": "ignore",
+        "track_on_post_machined_layer": "error",
+        "track_segment_length": "error",
+        "track_width": "error",
+        "tracks_crossing": "error",
+        "tuning_profile_track_geometries": "ignore",
+        "unconnected_items": "error",
+        "unresolved_variable": "error",
+        "via_dangling": "warning",
+        "zones_intersect": "error"
+      },
+      "rules": {
+        "max_error": 0.005,
+        "min_clearance": 0.0,
+        "min_connection": 0.0,
+        "min_copper_edge_clearance": 0.5,
+        "min_groove_width": 0.0,
+        "min_hole_clearance": 0.25,
+        "min_hole_to_hole": 0.25,
+        "min_microvia_diameter": 0.2,
+        "min_microvia_drill": 0.1,
+        "min_resolved_spokes": 2,
+        "min_silk_clearance": 0.0,
+        "min_text_height": 0.8,
+        "min_text_thickness": 0.08,
+        "min_through_hole_diameter": 0.3,
+        "min_track_width": 0.2,
+        "min_via_annular_width": 0.1,
+        "min_via_diameter": 0.5,
+        "solder_mask_to_copper_clearance": 0.0,
+        "use_height_for_length_calcs": true
+      },
+      "teardrop_options": [
+        {
+          "td_onpthpad": true,
+          "td_onroundshapesonly": false,
+          "td_onsmdpad": true,
+          "td_ontrackend": false,
+          "td_onvia": true
+        }
+      ],
+      "teardrop_parameters": [
+        {
+          "td_allow_use_two_tracks": true,
+          "td_curve_segcount": 0,
+          "td_height_ratio": 1.0,
+          "td_length_ratio": 0.5,
+          "td_maxheight": 2.0,
+          "td_maxlen": 1.0,
+          "td_on_pad_in_zone": false,
+          "td_target_name": "td_round_shape",
+          "td_width_to_size_filter_ratio": 0.9
+        },
+        {
+          "td_allow_use_two_tracks": true,
+          "td_curve_segcount": 0,
+          "td_height_ratio": 1.0,
+          "td_length_ratio": 0.5,
+          "td_maxheight": 2.0,
+          "td_maxlen": 1.0,
+          "td_on_pad_in_zone": false,
+          "td_target_name": "td_rect_shape",
+          "td_width_to_size_filter_ratio": 0.9
+        },
+        {
+          "td_allow_use_two_tracks": true,
+          "td_curve_segcount": 0,
+          "td_height_ratio": 1.0,
+          "td_length_ratio": 0.5,
+          "td_maxheight": 2.0,
+          "td_maxlen": 1.0,
+          "td_on_pad_in_zone": false,
+          "td_target_name": "td_track_end",
+          "td_width_to_size_filter_ratio": 0.9
+        }
+      ],
+      "track_widths": [
+        0.0,
+        0.127,
+        0.254,
+        0.508,
+        0.635,
+        1.27
+      ],
+      "tuning_pattern_settings": {
+        "diff_pair_defaults": {
+          "corner_radius_percentage": 80,
+          "corner_style": 1,
+          "max_amplitude": 1.0,
+          "min_amplitude": 0.2,
+          "single_sided": false,
+          "spacing": 1.0
+        },
+        "diff_pair_skew_defaults": {
+          "corner_radius_percentage": 80,
+          "corner_style": 1,
+          "max_amplitude": 1.0,
+          "min_amplitude": 0.2,
+          "single_sided": false,
+          "spacing": 0.6
+        },
+        "single_track_defaults": {
+          "corner_radius_percentage": 80,
+          "corner_style": 1,
+          "max_amplitude": 1.0,
+          "min_amplitude": 0.2,
+          "single_sided": false,
+          "spacing": 0.6
+        }
+      },
+      "via_dimensions": [
+        {
+          "diameter": 0.0,
+          "drill": 0.0
+        }
+      ],
+      "zones_allow_external_fillets": false
+    },
     "ipc2581": {
       "bom_rev": "",
       "dist": "",
@@ -8,7 +351,7 @@
       "internal_id": "",
       "mfg": "",
       "mpn": "",
-      "sch_revision": "0"
+      "sch_revision": "1"
     },
     "layer_pairs": [],
     "layer_presets": [],
@@ -416,7 +759,7 @@
         "uuid": "d6486f66-f0ec-4484-bce4-0ec6b0e57e1d"
       }
     ],
-    "used_designators": "#FLG1-2,R2-3,J4,#PWR3-6,D5-6,C2-6,L1,U1-2",
+    "used_designators": "J1-2",
     "variants": []
   },
   "sheets": [

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

@@ -1,288 +0,0 @@
-/*
-    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.");
-}