fix the blown up demo and update it for the docs

Signed-off-by: Brian S. Stephan <bss@incorporeal.org>

Makefile

@@ -1,4 +1,5 @@
 SRC_FILES := $(wildcard ./src/*.scad)
+SRC_FILES := $(filter-out ./src/all-together-demo.scad, $(SRC_FILES))
 SRC_FILES := $(filter-out ./src/blown-up-demo.scad, $(SRC_FILES))
 SRC_FILES := $(filter-out ./src/components.scad, $(SRC_FILES))
 SRC_FILES := $(filter-out ./src/roundedcube.scad, $(SRC_FILES))

README.md

@@ -2,7 +2,7 @@
 
 Files for 3D printing an arcade stick.
 
-![An example of stick components displayed in OpenSCAD](docs/two-panel-example-v3.png)
+![An example of stick components displayed in OpenSCAD](docs/blown-up-demo.png)
 
 [OpenSCAD-based illustration of how the components for an overhang panel-based stick fit together.]
 
@@ -28,6 +28,10 @@ These items all fit on a 256mm^2 print bed; I use a Bambu Lab P1P based on what
 OpenStickCommunity. Standard settings seem sufficiently sturdy for my purposes, though the slicer has done a couple
 weird things, in my experience.
 
+My preferred settings are 3 wall loops with 20% gyroid sparse infill. This gives the models a bit more weight and
+stability, but something like 2 wall loops, 15% grid sparse infill is fine and does not lead to a weak enclosure. The
+costs below have been made against my settings.
+
 ## Assembling
 
 What you'll need beyond these objects:
@@ -59,10 +63,10 @@ What you'll need beyond these objects:
 This is a rough estimate of the cost to produce one of these sticks, assuming a usual 2-frame design and layout.
 Filament masses from Bambu Studio estimates, using Bambu PLA Basic.
 
-* Left and right frame: **$7.08 USD** (141.84g each, as of 2023-09-12)
-* Left and right (overhang) top panels: **~$6.74 USD** (~135g each, as of 2023-09-12)
-* Left and right (overhang) bottom panels: **$5.90 USD** (118.16g each, as of 2023-09-12)
-* Miscellaneous mounting plates, decorative plates, etc.: **~$1.00 USD** (~40g, as of 2023-09-12)
+* Left and right frame: **$10.42 USD** (208.50g each, as of 2024-02-22)
+* Left and right (inset) top panels: **~$6.40 USD** (~128g each, as of 2024-02-22)
+* Left and right (non-overhang) bottom panels: **$6.80 USD** (135.99g each, as of 2024-02-22)
+* Miscellaneous mounting plates, decorative plates, etc.: **~$1.83 USD** (~73g, as of 2024-02-22)
 * 8 16mm M4 bolts to connect the frames: **$0.72 USD** (you can get a pack of 100 on Amazon for $9, as of 2023-09-12)
 * 8 M4 flange nuts to connect the frames: **$0.68 USD** (you can get a pack of 100 on Amazon for $8.50, as of 2023-09-12)
 * 4 10mm M3 bolts to connect Neutrik D plates to frames: **$0.40 USD** (you can get a pack of 100 on Amazon for $10, as
@@ -79,9 +83,10 @@ Filament masses from Bambu Studio estimates, using Bambu PLA Basic.
 * 8 12mm M4 bolts to connect bottom plates to frames: **$0.72 USD** (you can get a pack of 100 on Amazon for $9, as of
   2023-09-12)
 
-With an enclosure coming in around $26, depending on your choices --- say, ~$30 for TheTrain's RP2040 Advanced Breakout
+With an enclosure coming in around $31, depending on your choices --- say, ~$30 for TheTrain's RP2040 Advanced Breakout
 Board, ~$60 for Sanwa buttons and a lever, and ~$20 for miscellaneous connectors and wiring --- you can put a
-full-featured controller with an open source foundation together for around $135.
+full-featured controller with an open source foundation together for around $140. Reducing wall and infill settings
+will probably save you around $5 of material, and you can probably decide what you want to do from there.
 
 ## Miscellany
 

src/blown-up-demo.scad

@@ -7,10 +7,10 @@ include <parameters.scad>
 include <components.scad>
 use <frame-left.scad>
 use <frame-right.scad>
-use <top-panel-left-lever-and-dir_arc-plus-w-30mm.scad>
-use <top-panel-right-sega-2p-plus-one-plus-control-with-mount.scad>
-use <bottom-panel-left.scad>
-use <bottom-panel-right.scad>
+use <top-panel-overhang-left-lever-and-dir_arc-plus-w-30mm.scad>
+use <top-panel-overhang-right-sega-2p-plus-one-plus-control-with-mount.scad>
+use <bottom-panel-overhang-left.scad>
+use <bottom-panel-overhang-right.scad>
 use <misc-decorative-plate-24mm-button.scad>
 use <misc-decorative-plate-dir_arc-plus-w-30mm-and-sega-2p-plus-one.scad>
 use <misc-dustwasher-lsx-nobi.scad>

src/components.scad

@@ -83,7 +83,7 @@ module rocker_20mm_mount() {
 
 // space for a neutrik D mount or 24mm button - Z is to cut the whole inside without affecting panel lip
 module frame_cutout() {
-	cube([30.5, 8, frame_z-(panel_z*2)], center=true);
+	cube([30.5, 8, frame_z-(panel_z*2)-2], center=true);
 }
 
 // bank of three 24mm buttons, commonly on a frame face
@@ -151,6 +151,9 @@ module levermountholes() {
 		m4_hole();
 	translate([-20, -42.5, 0])
 		m4_hole();
+}
+
+module levermountcountersinks() {
 	// holes for joystick bolt countersinks
 	translate([20, 42.5, 2])
 		m4_hole_countersink();

src/frame-left.scad

@@ -25,14 +25,14 @@ module left_frame() {
 
 		// aux button holes
 		translate([-35, 101.5, panel_z/2]) rotate([270, 0, 0]) aux_control_three_button_cluster();
-		translate([-35, (frame_y/2)-neutrik_panel_thickness-4, 0]) frame_cutout();
-		translate([-72, (frame_y/2)-neutrik_panel_thickness-4, 0]) frame_cutout();
-		translate([2, (frame_y/2)-neutrik_panel_thickness-4, 0]) frame_cutout();
+		translate([-35, (frame_y/2)-neutrik_panel_thickness-4, 1]) frame_cutout();
+		translate([-72, (frame_y/2)-neutrik_panel_thickness-4, 1]) frame_cutout();
+		translate([2, (frame_y/2)-neutrik_panel_thickness-4, 1]) frame_cutout();
 
 		// neutrix button hole
 		translate([frame_center_to_neutrik, (frame_y/2)-neutrik_panel_thickness, panel_z/2])
 			rotate([90, 0, 0]) neutrik_d_mount();
-		translate([frame_center_to_neutrik, (frame_y/2)-neutrik_panel_thickness-4, 0])
+		translate([frame_center_to_neutrik, (frame_y/2)-neutrik_panel_thickness-4, 1])
 			frame_cutout();
 	}
 }

src/frame-middle.scad

@@ -29,13 +29,13 @@ module middle_frame() {
 		// neutrik mounts for connector, switches
 		translate([0, (frame_y/2)-neutrik_panel_thickness, panel_z/2])
 			rotate([90, 0, 0]) neutrik_d_mount();
-		translate([0, (frame_y/2)-neutrik_panel_thickness-4, 0]) frame_cutout();
+		translate([0, (frame_y/2)-neutrik_panel_thickness-4, 1]) frame_cutout();
 		translate([-40, (frame_y/2)-neutrik_panel_thickness, panel_z/2])
 			rotate([90, 0, 0]) neutrik_d_mount();
-		translate([-40, (frame_y/2)-neutrik_panel_thickness-4, 0]) frame_cutout();
+		translate([-40, (frame_y/2)-neutrik_panel_thickness-4, 1]) frame_cutout();
 		translate([40, (frame_y/2)-neutrik_panel_thickness, panel_z/2])
 			rotate([90, 0, 0]) neutrik_d_mount();
-		translate([40, (frame_y/2)-neutrik_panel_thickness-4, 0]) frame_cutout();
+		translate([40, (frame_y/2)-neutrik_panel_thickness-4, 1]) frame_cutout();
 	}
 }
 

src/frame-right.scad

@@ -25,14 +25,14 @@ module right_frame() {
 
 		// aux button holes
 		translate([35, 101.5, panel_z/2]) rotate([270, 0, 0]) aux_control_three_button_cluster();
-		translate([35, (frame_y/2)-neutrik_panel_thickness-4, 0]) frame_cutout();
-		translate([72, (frame_y/2)-neutrik_panel_thickness-4, 0]) frame_cutout();
-		translate([-2, (frame_y/2)-neutrik_panel_thickness-4, 0]) frame_cutout();
+		translate([35, (frame_y/2)-neutrik_panel_thickness-4, 1]) frame_cutout();
+		translate([72, (frame_y/2)-neutrik_panel_thickness-4, 1]) frame_cutout();
+		translate([-2, (frame_y/2)-neutrik_panel_thickness-4, 1]) frame_cutout();
 
 		// neutrix button hole
 		translate([-frame_center_to_neutrik, (frame_y/2)-neutrik_panel_thickness, panel_z/2])
 			rotate([90, 0, 0]) neutrik_d_mount();
-		translate([-frame_center_to_neutrik, (frame_y/2)-neutrik_panel_thickness-4, 0])
+		translate([-frame_center_to_neutrik, (frame_y/2)-neutrik_panel_thickness-4, 1])
 			frame_cutout();
 	}
 }

src/frame-solo.scad

@@ -12,24 +12,24 @@ module solo_frame() {
 
 		// neutrik mounts for connector, switches
 		translate([0, (frame_y/2)-2.5, panel_z/2]) rotate([90, 0, 0]) neutrik_d_mount();
-		translate([0, (frame_y/2)-neutrik_panel_thickness-4, 0]) frame_cutout();
+		translate([0, (frame_y/2)-neutrik_panel_thickness-4, 1]) frame_cutout();
 		translate([-40, (frame_y/2)-2.5, panel_z/2]) rotate([90, 0, 0]) neutrik_d_mount();
-		translate([-40, (frame_y/2)-neutrik_panel_thickness-4, 0]) frame_cutout();
+		translate([-40, (frame_y/2)-neutrik_panel_thickness-4, 1]) frame_cutout();
 		translate([40, (frame_y/2)-2.5, panel_z/2]) rotate([90, 0, 0]) neutrik_d_mount();
-		translate([40, (frame_y/2)-neutrik_panel_thickness-4, 0]) frame_cutout();
+		translate([40, (frame_y/2)-neutrik_panel_thickness-4, 1]) frame_cutout();
 
 		// aux button holes
 		translate([-frame_x/2+2.5, 0, panel_z/2]) rotate([90, 0, 270])
 			aux_control_three_button_cluster();
-		translate([(frame_x/2)-neutrik_panel_thickness-4, 0, 0]) rotate([0, 0, 90]) frame_cutout();
-		translate([(frame_x/2)-neutrik_panel_thickness-4, -37, 0]) rotate([0, 0, 90]) frame_cutout();
-		translate([(frame_x/2)-neutrik_panel_thickness-4, 37, 0]) rotate([0, 0, 90]) frame_cutout();
+		translate([(frame_x/2)-neutrik_panel_thickness-4, 0, 1]) rotate([0, 0, 90]) frame_cutout();
+		translate([(frame_x/2)-neutrik_panel_thickness-4, -37, 1]) rotate([0, 0, 90]) frame_cutout();
+		translate([(frame_x/2)-neutrik_panel_thickness-4, 37, 1]) rotate([0, 0, 90]) frame_cutout();
 
 		translate([frame_x/2+2.5, 0, panel_z/2]) rotate([90, 0, 270])
 			aux_control_three_button_cluster();
-		translate([-(frame_x/2)+neutrik_panel_thickness+4, 0, 0]) rotate([0, 0, 90]) frame_cutout();
-		translate([-(frame_x/2)+neutrik_panel_thickness+4, -37, 0]) rotate([0, 0, 90]) frame_cutout();
-		translate([-(frame_x/2)+neutrik_panel_thickness+4, 37, 0]) rotate([0, 0, 90]) frame_cutout();
+		translate([-(frame_x/2)+neutrik_panel_thickness+4, 0, 1]) rotate([0, 0, 90]) frame_cutout();
+		translate([-(frame_x/2)+neutrik_panel_thickness+4, -37, 1]) rotate([0, 0, 90]) frame_cutout();
+		translate([-(frame_x/2)+neutrik_panel_thickness+4, 37, 1]) rotate([0, 0, 90]) frame_cutout();
 	}
 }
 

src/misc-lever-mount-sanwa-seimitsu.scad

@@ -0,0 +1,16 @@
+/*
+ * SPDX-FileCopyrightText: © 2023 Brian S. Stephan <bss@incorporeal.org>
+ * SPDX-License-Identifier: GPL-3.0-or-later
+ */
+
+include <parameters.scad>
+include <components.scad>
+
+module sanwa_seimitsu_lever_mount() {
+	difference() {
+		levermountbase();
+		levermountholes();
+	}
+}
+
+sanwa_seimitsu_lever_mount();

src/top-panel-inset-lever-and-dir_arc-plus-w-30mm.scad

@@ -8,13 +8,10 @@ include <components.scad>
 
 module top_panel_inset_lever_and_dir_arc_w_30mm() {
 	difference() {
-		union() {
-			panel();
-			translate([(-panel_x/2)+55, (panel_y/2)-75, -((panel_z/2)+(lever_mount_z/2))])
-				levermountbase();
-		}
+		panel();
 		dir_arc_w_30mm();
 		translate([(-panel_x/2)+55, (panel_y/2)-75, 0]) levermountholes();
+		translate([(-panel_x/2)+55, (panel_y/2)-75, 0]) levermountcountersinks();
 	}
 }
 

src/top-panel-inset-lever.scad

@@ -10,12 +10,10 @@ include <components.scad>
 module lever_panel() {
 	difference() {
 		// base plate
-		union() {
-			translate([0,-20,0]) panel();
-			translate([0, 0, -((panel_z/2)+(lever_mount_z/2))]) levermountbase();
-		}
+		translate([0,-20,0]) panel();
 		// holes to mount the lever
 		levermountholes();
+		levermountcountersinks();
 	}
 }
 

src/top-panel-overhang-left-lever-and-dir_arc-plus-w-30mm.scad

@@ -8,13 +8,11 @@ include <components.scad>
 
 module top_panel_left_lever_and_dir_arc_w_30mm() {
 	difference() {
-		union() {
-			panel_with_raised_overhang();
-			translate([(-panel_x/2)+55, (panel_y/2)-75, -((panel_z/2)+(lever_mount_z/2))]) levermountbase();
-		}
+		panel_with_raised_overhang();
 		dir_arc_w_30mm();
 		side_chopper();
 		translate([(-panel_x/2)+55, (panel_y/2)-75, 0]) levermountholes();
+		translate([(-panel_x/2)+55, (panel_y/2)-75, 0]) levermountcountersinks();
 	}
 }
 

src/top-panel-overhang-left-lever.scad

@@ -10,12 +10,10 @@ include <components.scad>
 module top_panel_left_lever() {
 	difference() {
 		// base plate
-		union() {
-			panel_with_raised_overhang();
-			translate([0, 0, -((panel_z/2)+(lever_mount_z/2))]) levermountbase();
-		}
+		panel_with_raised_overhang();
 		// holes to mount the lever
 		translate([0, 20, 0]) levermountholes();
+		translate([0, 20, 0]) levermountcountersinks();
 		side_chopper();
 	}
 }