add mount for a standard PS360+/RP2040ABB form factor PCB

trying to shave a couple mm off the design to make room for this Seimitsu SEL-70X-F

TODO.md

@@ -0,0 +1,10 @@
+# TODO
+
+Notes for "next time".
+
+## v2
+
+* I need at least 5mm, maybe 10mm, more height, to fit some of my levers like the Nobi Bullet
+* The panels' connection points could probably be a bit thinner to accommodate more bolts. A 20mm bolt barely clears the
+  two panels and I don't like that kind of bolt connection.
+* Engraving some cosmetic stuff? Or maybe a place to mount other plates?

src/bottom-panel.scad

@@ -0,0 +1,25 @@
+/* Copyright Brian Stephan 2023
+ *
+ * This file is part of bullet-system-stick.
+ *
+ * bullet-system-stick is free software: you can redistribute it and/or modify
+ * it under the terms of the GNU General Public License as published by the
+ * Free Software Foundation, either version 3 of the License, or (at your
+ * option) any later version.
+ *
+ * bullet-system-stick is distributed in the hope that it will be useful, but
+ * WITHOUT ANY WARRANTY; without even the implied warranty of MERCHANTABILITY
+ * or FITNESS FOR A PARTICULAR PURPOSE. See the GNU General Public License for
+ * more details.
+ *
+ * You should have received a copy of the GNU General Public License along with
+ * bullet-system-stick. If not, see <https://www.gnu.org/licenses/>.
+ */
+
+include <components.scad>
+
+module bottom_panel() {
+	mirror([0, 0, 1]) topplate();
+}
+
+bottom_panel();

src/components.scad

@@ -16,11 +16,16 @@
  * bullet-system-stick. If not, see <https://www.gnu.org/licenses/>.
  */
 
+include <roundedcube.scad>
+
 /* QUASI-CONSTANTS */
 
 // adjustments
 hole_tolerance = 0.15;
 
+// M3
+m3_screw_selftap_radius = 1.3;
+
 // M4
 m4_bolt_radius = 2 + hole_tolerance;
 m4_bolt_countersink_radius = 6.1 + hole_tolerance;
@@ -32,10 +37,15 @@ small_button_radius = 12 + hole_tolerance;
 // 30mm button
 big_button_radius = 15 + hole_tolerance;
 
+// JLF mount dimensions
+lever_mount_x = 53;
+lever_mount_y = 95;
+lever_mount_z = 2;
+
 // case dimensions
-frame_x = 185;
+frame_x = 183;
-frame_y = 210;
+frame_y = 208;
-frame_z = 45;
+frame_z = 45;			// reminder: inside (including mounts) is chopped by top_plate_z for plates
 top_plate_x = 175;
 top_plate_y = 200;
 top_plate_z = 5;
@@ -84,12 +94,26 @@ module neutrik_d_mount() {
 	translate([-9.5, -12, 0]) neutrik_d_screw_hole();
 }
 
+module m3_mount_post() {
+	difference() {
+		cylinder(r=m3_screw_selftap_radius*4, h=8, $fn=6, center=true);
+		cylinder(r=m3_screw_selftap_radius, h=8*2, $fn=50, center=true);
+	}
+}
+
+module pcb_mount() {
+	translate([44, 18.5, 0]) m3_mount_post();
+	translate([44, -18.5, 0]) m3_mount_post();
+	translate([-44, 18.5, 0]) m3_mount_post();
+	translate([-44, -18.5, 0]) m3_mount_post();
+}
+
 /* PIECES */
 
 module levermountbase() {
 	difference() {
 		// base plate
-		cube([53,95,3], center=true);
+		cube([lever_mount_x, lever_mount_y, lever_mount_z], center=true);
 		// joystick hole
 		cylinder(r=21, h=3.1, $fn=50, center=true);
 	}
@@ -150,8 +174,8 @@ module topplate() {
 
 module frame_box() {
 	difference() {
-		cube([frame_x, frame_y, frame_z], center=true);
+		roundedcube([frame_x, frame_y, frame_z], center=true, radius=3);
-		cube([160, 185, frame_z+5], center=true);
+		cube([frame_x-26, frame_y-26, frame_z+5], center=true);
 	}
 }
 
@@ -159,15 +183,8 @@ module frame_mount_column() {
 	cube([20, 20, frame_z], center=true);
 }
 
-module frame_panel_surround() {
-	difference() {
-		cube([frame_x, frame_y, top_plate_z], center=true);
-		scale([1, 1, 2]) base_topplate();
-	}
-}
-
 module frame_side_chopper() {
-	translate([frame_x/2, 0, 0]) cube([10.001, 2*(frame_y+top_plate_y), 2*(frame_z+top_plate_z)], center=true);
+	translate([frame_x/2, 0, 0]) cube([8, 2*(frame_y+top_plate_y), 2*(frame_z+top_plate_z)], center=true);
 }
 
 module frame_connection_holes() {
@@ -188,8 +205,6 @@ module frame_cable_routing_hole() {
 
 module base_frame() {
 	frame_box();
-	translate([0, 0, frame_z/2 + top_plate_z/2])
-		frame_panel_surround();
 	translate([(top_plate_x/2)-10, (top_plate_y/2)-10, 0])
 		frame_mount_column();
 	translate([-((top_plate_x/2)-10), (top_plate_y/2)-10, 0])
@@ -203,6 +218,7 @@ module base_frame() {
 module frame() {
 	difference() {
 		base_frame();
+		translate([0, 0, frame_z/2]) scale([1, 1, 2]) base_topplate();
 		translate([(top_plate_x/2)-10, (top_plate_y/2)-10, 0])
 			frame_hex_bolt_hole();
 		translate([-((top_plate_x/2)-10), (top_plate_y/2)-10, 0])
@@ -211,6 +227,9 @@ module frame() {
 			frame_hex_bolt_hole();
 		translate([-((top_plate_x/2)-10), -((top_plate_y/2)-10), 0])
 			frame_hex_bolt_hole();
+
+		// thin up the mount point to accommodate snap-ins, ethercon adapter
+		translate([0, 10, 10]) cube([120, 180, 60], center=true);
 	}
 }
 

src/frame-left.scad

@@ -30,10 +30,15 @@ module left_frame() {
 	difference() {
 		base_left_frame();
 		// connection holes to other frames
-		frame_connection_holes();
+		translate([0, 0, -top_plate_z/2]) frame_connection_holes();
 
 		// cable routing hole
-		frame_cable_routing_hole();
+		translate([0, 0, -top_plate_z/2]) frame_cable_routing_hole();
+
+		// aux button holes
+		translate([0, 100, 0]) rotate([90, 0, 0]) button_24mm_hole();
+		translate([-40, 100, 0]) rotate([90, 0, 0]) button_24mm_hole();
+		translate([40, 100, 0]) rotate([90, 0, 0]) button_24mm_hole();
 	}
 }
 

src/frame-middle.scad

@@ -18,7 +18,7 @@
 
 include <components.scad>
 
-module middle_frame() {
+module base_middle_frame() {
 	difference() {
 		frame();
 		// chop the left and right edge off
@@ -27,18 +27,22 @@ module middle_frame() {
 	}
 }
 
-difference() {
+module middle_frame() {
-	middle_frame();
+	difference() {
-	// connection holes to other frames
+		base_middle_frame();
-	frame_connection_holes();
+		// connection holes to other frames
-	mirror([1, 0, 0]) frame_connection_holes();
+		translate([0, 0, -top_plate_z/2]) frame_connection_holes();
+		translate([0, 0, -top_plate_z/2]) mirror([1, 0, 0]) frame_connection_holes();
 
-	// cable routing holes
+		// cable routing holes
-	frame_cable_routing_hole();
+		translate([0, 0, -top_plate_z/2]) frame_cable_routing_hole();
-	mirror([1, 0, 0]) frame_cable_routing_hole();
+		translate([0, 0, -top_plate_z/2]) mirror([1, 0, 0]) frame_cable_routing_hole();
 
-	// neutrik mounts for connector, switches
+		// neutrik mounts for connector, switches
-	translate([0, 100, 0]) rotate([90, 0, 0]) neutrik_d_mount();
+		translate([0, 100, 0]) rotate([90, 0, 0]) neutrik_d_mount();
-	translate([-40, 100, 0]) rotate([90, 0, 0]) neutrik_d_mount();
+		translate([-40, 100, 0]) rotate([90, 0, 0]) neutrik_d_mount();
-	translate([40, 100, 0]) rotate([90, 0, 0]) neutrik_d_mount();
+		translate([40, 100, 0]) rotate([90, 0, 0]) neutrik_d_mount();
+	}
 }
+
+middle_frame();

src/frame-right.scad

@@ -0,0 +1,26 @@
+/* Copyright Brian Stephan 2023
+ *
+ * This file is part of bullet-system-stick.
+ *
+ * bullet-system-stick is free software: you can redistribute it and/or modify
+ * it under the terms of the GNU General Public License as published by the
+ * Free Software Foundation, either version 3 of the License, or (at your
+ * option) any later version.
+ *
+ * bullet-system-stick is distributed in the hope that it will be useful, but
+ * WITHOUT ANY WARRANTY; without even the implied warranty of MERCHANTABILITY
+ * or FITNESS FOR A PARTICULAR PURPOSE. See the GNU General Public License for
+ * more details.
+ *
+ * You should have received a copy of the GNU General Public License along with
+ * bullet-system-stick. If not, see <https://www.gnu.org/licenses/>.
+ */
+
+include <components.scad>
+use <frame-left.scad>
+
+module right_frame() {
+	mirror([1, 0, 0]) left_frame();
+}
+
+right_frame();

src/roundedcube.scad

@@ -0,0 +1,55 @@
+// More information: https://danielupshaw.com/openscad-rounded-corners/
+
+// Set to 0.01 for higher definition curves (renders slower)
+$fs = 0.15;
+
+module roundedcube(size = [1, 1, 1], center = false, radius = 0.5, apply_to = "all") {
+	// If single value, convert to [x, y, z] vector
+	size = (size[0] == undef) ? [size, size, size] : size;
+
+	translate_min = radius;
+	translate_xmax = size[0] - radius;
+	translate_ymax = size[1] - radius;
+	translate_zmax = size[2] - radius;
+
+	diameter = radius * 2;
+
+	obj_translate = (center == false) ?
+		[0, 0, 0] : [
+			-(size[0] / 2),
+			-(size[1] / 2),
+			-(size[2] / 2)
+		];
+
+	translate(v = obj_translate) {
+		hull() {
+			for (translate_x = [translate_min, translate_xmax]) {
+				x_at = (translate_x == translate_min) ? "min" : "max";
+				for (translate_y = [translate_min, translate_ymax]) {
+					y_at = (translate_y == translate_min) ? "min" : "max";
+					for (translate_z = [translate_min, translate_zmax]) {
+						z_at = (translate_z == translate_min) ? "min" : "max";
+
+						translate(v = [translate_x, translate_y, translate_z])
+						if (
+							(apply_to == "all") ||
+							(apply_to == "xmin" && x_at == "min") || (apply_to == "xmax" && x_at == "max") ||
+							(apply_to == "ymin" && y_at == "min") || (apply_to == "ymax" && y_at == "max") ||
+							(apply_to == "zmin" && z_at == "min") || (apply_to == "zmax" && z_at == "max")
+						) {
+							sphere(r = radius);
+						} else {
+							rotate = 
+								(apply_to == "xmin" || apply_to == "xmax" || apply_to == "x") ? [0, 90, 0] : (
+								(apply_to == "ymin" || apply_to == "ymax" || apply_to == "y") ? [90, 90, 0] :
+								[0, 0, 0]
+							);
+							rotate(a = rotate)
+							cylinder(h = diameter, r = radius, center = true);
+						}
+					}
+				}
+			}
+		}
+	}
+}

src/top-panel-left-lever.scad

@@ -25,12 +25,16 @@ module left_lever_panel() {
 		union() {
 			translate([20,-20,0])
 				topplate();
-			translate([0,0,-4])
+			translate([0, 0, -((top_plate_z/2)+(lever_mount_z/2))]) levermountbase();
-				levermountbase();
 		}
 		// holes to mount the lever
 		levermountholes();
 	}
 }
 
-left_lever_panel();
+module left_lever_panel_with_mount() {
+	left_lever_panel();
+	translate([0, -top_plate_y/2+25, -(top_plate_z/2) - 3]) pcb_mount();
+}
+
+left_lever_panel_with_mount();

src/top-panel-lever.scad

@@ -0,0 +1,41 @@
+/* Copyright Brian Stephan 2023
+ *
+ * This file is part of bullet-system-stick.
+ *
+ * bullet-system-stick is free software: you can redistribute it and/or modify
+ * it under the terms of the GNU General Public License as published by the
+ * Free Software Foundation, either version 3 of the License, or (at your
+ * option) any later version.
+ *
+ * bullet-system-stick is distributed in the hope that it will be useful, but
+ * WITHOUT ANY WARRANTY; without even the implied warranty of MERCHANTABILITY
+ * or FITNESS FOR A PARTICULAR PURPOSE. See the GNU General Public License for
+ * more details.
+ *
+ * You should have received a copy of the GNU General Public License along with
+ * bullet-system-stick. If not, see <https://www.gnu.org/licenses/>.
+ */
+
+include <components.scad>
+
+// combine the lever mount and generic plate, with mounting holes
+module lever_panel() {
+	difference() {
+		// base plate
+		union() {
+			translate([0,-20,0])
+				topplate();
+			translate([0, 0, -((top_plate_z/2)+(lever_mount_z/2))])
+				levermountbase();
+		}
+		// holes to mount the lever
+		levermountholes();
+	}
+}
+
+module lever_panel_with_mount() {
+	lever_panel();
+	translate([0, -top_plate_y/2+25, -(top_plate_z/2) - 3]) pcb_mount();
+}
+
+lever_panel_with_mount();