standalone frame, with tweaks to the frame as a consequence

* frame width has been reduced in order to leave more space and have
  sunken buttons somewhat accessible
* the cutout for neutrik mounts has been reduced and moved into the
  holes themselves, to do this more modularly and restore some support

README.md

@@ -45,13 +45,10 @@ What you'll need beyond these objects:
 
 This is a living repository, and as such, there are likely issues with the objects, known or otherwise. Be aware:
 
-* The top panel is 5mm tall and doesn't have an inset; snap-in buttons likely do not fit.
 * A composition error made the frame 5mm shorter than intended and wasn't noticed until I printed everything:
     * Some levers don't have enough clearance in the case.
     * Buttons with traditional quick connects are a *very* tight fit, you will probably need to bend pins.
 * The PCB mount position was very tight on the buttons panel; it will probably have to be moved.
-* Support for the top plate was removed from the frame due to overhang issues, and now the top plate can bow slightly
-  with pressure; a new solution needs to be found.
 
 These issues may be fixed in the future; see `TODO.md` for details.
 

TODO.md

@@ -7,12 +7,8 @@ Notes for "next time".
 * I need at least 5mm, maybe 10mm, more height, to fit some of my levers like the Nobi Bullet
     * I couldn't even fit a JLF without the compensations in v1 on the bottom panel
     * I had to bend the pins a bit on Crown SDB-202s, too
-* Top plates are 1-2mm too thick for snap-ins, maybe have a variant with a couple shaved off like with the bottom plate
-  workaround
 * The plates bow a bit on the top when pressure is applied, because there's no support from the frame up there ---
   adding 5mm to the frame should leave a couple mm for support to get added back
 * PCB mount on `top-panel-dir_arc-plus-w-30mm-plus-one-with-mount.scad` doesn't leave room for a USB cable on the right
   hand side
-* 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/components.scad

@@ -50,6 +50,9 @@ top_plate_x = 175;
 top_plate_y = 200;
 top_plate_z = 5;
 
+// frame interior that supports the top plates
+panel_support_width = 5;
+
 // neutrik D screw holes
 neutrik_d_screw_radius = 1.6 + hole_tolerance;
 neutrik_d_radius = 12 + hole_tolerance;
@@ -64,14 +67,43 @@ module m4_hole_countersink() {
 	cylinder(r1=m4_bolt_radius, r2=m4_bolt_countersink_radius, h=3.2, $fn=50, center=true);
 }
 
+module top_plate_holes() {
+	// holes for mount bolts
+	translate([77.5, 90, 0]) m4_hole();
+	translate([77.5, -90, 0]) m4_hole();
+	translate([-77.5, 90, 0]) m4_hole();
+	translate([-77.5, -90, 0]) m4_hole();
+	// holes for mount bolt countersinks
+	translate([77.5, 90, 2]) m4_hole_countersink();
+	translate([77.5, -90, 2]) m4_hole_countersink();
+	translate([-77.5, 90, 2]) m4_hole_countersink();
+	translate([-77.5, -90, 2]) m4_hole_countersink();
+}
+
 module button_24mm_hole() {
 	cylinder(r=small_button_radius, h=100, $fn=50, center=true);
 }
 
+module button_24mm_hole_for_snapins() {
+	button_24mm_hole();
+	// carve out space for snap-ins, leave 3mm
+	// slagcoin has screw-in nut diameter at 29.5mm, so radius+6 to leave some space
+	// translation is to leave 3mm thickness in the plate without recentering anything
+	translate([0, 0, -25]) cylinder(r=small_button_radius+6, h=49, $fn=50, center=true);
+}
+
 module button_30mm_hole() {
 	cylinder(r=big_button_radius, h=100, $fn=50, center=true);
 }
 
+module button_30mm_hole_for_snapins() {
+	button_30mm_hole();
+	// carve out space for snap-ins, leave 3mm
+	// slagcoin has screw-in nut diameter at 36mm, so radius+6 to leave some space
+	// translation is to leave 3mm thickness in the plate without recentering anything
+	translate([0, 0, -25]) cylinder(r=big_button_radius+6, h=49, $fn=50, center=true);
+}
+
 module frame_hex_bolt_hole() {
 	scale([1, 1, 2]) cylinder(r=m4_bolt_hex_exterior_radius, h=frame_z, $fn=6, center=true);
 }
@@ -92,6 +124,7 @@ module neutrik_d_mount() {
 	neutrik_d_hole();
 	translate([9.5, 12, 0]) neutrik_d_screw_hole();
 	translate([-9.5, -12, 0]) neutrik_d_screw_hole();
+	translate([0, 0, 25]) cube([32, 37, 50], center=true);
 }
 
 module m3_mount_post() {
@@ -148,34 +181,40 @@ module base_topplate() {
 	cube([top_plate_x, top_plate_y, top_plate_z], center=true);
 }
 
+// this takes the base_topplate and makes it a small frame, putting a larger top plate
+module base_topplate_with_raised_overhang() {
+	// make a frame out of the top plate (and keep the main plate on the center plane)
+	translate([0, 0, -5]) difference() {
+		base_topplate();
+		cube([top_plate_x-(panel_support_width*2), top_plate_y-(panel_support_width*2), top_plate_z*2], center=true);
+	}
+	translate([(top_plate_x/2)-10, (top_plate_y/2)-10, -2.5]) resize([0, 0, 10]) frame_mount_column();
+	translate([-((top_plate_x/2)-10), (top_plate_y/2)-10, -2.5]) resize([0, 0, 10]) frame_mount_column();
+	translate([(top_plate_x/2)-10, -((top_plate_y/2)-10), -2.5]) resize([0, 0, 10]) frame_mount_column();
+	translate([-((top_plate_x/2)-10), -((top_plate_y/2)-10), -2.5]) resize([0, 0, 10]) frame_mount_column();
+
+	// larger top plate
+	roundedcube([top_plate_x+25, top_plate_y+25, top_plate_z], center=true, radius=1);
+}
+
 module topplate() {
 	difference() {
 		base_topplate();
-		// holes for mount bolts
+		top_plate_holes();
-		translate([77.5, 90, 0])
+	}
-			m4_hole();
+}
-		translate([77.5, -90, 0])
+
-			m4_hole();
+module topplate_with_raised_overhang() {
-		translate([-77.5, 90, 0])
+	difference() {
-			m4_hole();
+		base_topplate_with_raised_overhang();
-		translate([-77.5, -90, 0])
+		top_plate_holes();
-			m4_hole();
-		// holes for mount bolt countersinks
-		translate([77.5, 90, 2])
-			m4_hole_countersink();
-		translate([77.5, -90, 2])
-			m4_hole_countersink();
-		translate([-77.5, 90, 2])
-			m4_hole_countersink();
-		translate([-77.5, -90, 2])
-			m4_hole_countersink();
 	}
 }
 
 module frame_box() {
 	difference() {
 		roundedcube([frame_x, frame_y, frame_z], center=true, radius=3);
-		cube([frame_x-26, frame_y-26, frame_z+5], center=true);
+		cube([frame_x-(panel_support_width*2), frame_y-(panel_support_width*2), frame_z+5], center=true);
 	}
 }
 
@@ -227,16 +266,32 @@ 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);
 	}
 }
 
 /* LAYOUTS */
 
+// Directional Arc (both hands)
+
+module dir_arc_24mm_combined_6_button() {
+	button_24mm_hole_for_snapins();
+	translate([29.5, 0, 0]) button_24mm_hole_for_snapins();
+	translate([29.5+26.3, -12.9, 0]) button_24mm_hole_for_snapins();
+
+	translate([29.5+26.3+15.5+9.7+2.6, 0, 0]) button_24mm_hole_for_snapins();
+	translate([29.5+26.3+15.5+9.7+2.6+26.9, 10.9, 0]) button_24mm_hole_for_snapins();
+	translate([29.5+26.3+15.5+9.7+2.6+26.9+29.6, 10.9, 0]) button_24mm_hole_for_snapins();
+	translate([29.5+26.3+15.5+9.7, -29.4, 0]) button_24mm_hole_for_snapins();
+	translate([29.5+26.3+15.5+9.7+2.6+26.9-1.7, 10.9-30.1, 0]) button_24mm_hole_for_snapins();
+	translate([29.5+26.3+15.5+9.7+2.6+26.9+29.6, 10.9-30.1, 0]) button_24mm_hole_for_snapins();
+
+	translate([29.5+26.3+15.5, -65.2, 0]) button_30mm_hole_for_snapins();
+}
+
+// Directional Arc (left hand)
+
 module dir_arc_30mm_button_l() {
-	translate([68, 132, 0]) button_30mm_hole();
+	translate([68, 132, 0]) button_30mm_hole_for_snapins();
 }
 
 module dir_arc_w_30mm() {
@@ -245,7 +300,7 @@ module dir_arc_w_30mm() {
 	translate([35+33.5, -12.9, 0]) dir_arc_30mm_button_l();
 	translate([35+7, 34.5, 0]) dir_arc_30mm_button_l();
 	// just my guesstimate on this one, but note that this is the same position as sega 2p (just mirrored)
-	translate([top_plate_x-33.06, 145-19-9-11-19-9-11, 0]) button_30mm_hole();
+	translate([top_plate_x-33.06, 145-19-9-11-19-9-11, 0]) button_30mm_hole_for_snapins();
 }
 
 module dir_arc_w_30mm_plus_one() {
@@ -253,8 +308,10 @@ module dir_arc_w_30mm_plus_one() {
 	translate([-33.5, -12.9, 0]) dir_arc_30mm_button_l();
 }
 
+// Namco Noir (right hand)
+
 module noir_button_p1() {
-	translate([40, 145, 0]) button_30mm_hole();
+	translate([40, 145, 0]) button_30mm_hole_for_snapins();
 }
 
 module noir_plus_one() {
@@ -272,8 +329,10 @@ module noir_plus_one() {
 	translate([-3.47-3.47, -78, 0]) noir_button_p1();
 }
 
+// Sega Astro City 2P (right hand)
+
 module sega_2p_p1() {
-	translate([33.06, 145, 0]) button_30mm_hole();
+	translate([33.06, 145, 0]) button_30mm_hole_for_snapins();
 }
 
 module sega_2p_plus_one() {

src/frame-solo.scad

@@ -0,0 +1,46 @@
+/* Copyright Brian Stephan 2023
+ *
+ * This file is part of the Buildable Stick System.
+ *
+ * The Buildable Stick System 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.
+ *
+ * The Buildable Stick System 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
+ * the Buildable Stick System. If not, see <https://www.gnu.org/licenses/>.
+ */
+
+include <components.scad>
+
+module solo_frame() {
+	difference() {
+		rotate([0, 0, 90]) frame();
+
+		// neutrik mounts for connector, switches
+		translate([0, (frame_x/2)-2.5, 0]) rotate([90, 0, 0]) neutrik_d_mount();
+		translate([-40, (frame_x/2)-2.5, 0]) rotate([270, 0, 0]) button_24mm_hole_for_snapins();
+		translate([40, (frame_x/2)-2.5, 0]) rotate([270, 0, 0]) button_24mm_hole_for_snapins();
+
+		// aux button holes
+		translate([-frame_y/2+2.5, 0, 0]) rotate([0, 0, 270])
+			translate([0, 0, 0]) rotate([90, 0, 0]) button_24mm_hole_for_snapins();
+		translate([-frame_y/2+2.5, 0, 0]) rotate([0, 0, 270])
+			translate([-40, 0, 0]) rotate([90, 0, 0]) button_24mm_hole_for_snapins();
+		translate([-frame_y/2+2.5, 0, 0]) rotate([0, 0, 270])
+			translate([40, 0, 0]) rotate([90, 0, 0]) button_24mm_hole_for_snapins();
+		translate([frame_y/2-2.5, 0, 0]) rotate([0, 0, 90])
+			translate([0, 0, 0]) rotate([90, 0, 0]) button_24mm_hole_for_snapins();
+		translate([frame_y/2-2.5, 0, 0]) rotate([0, 0, 90])
+			translate([-40, 0, 0]) rotate([90, 0, 0]) button_24mm_hole_for_snapins();
+		translate([frame_y/2-2.5, 0, 0]) rotate([0, 0, 90])
+			translate([40, 0, 0]) rotate([90, 0, 0]) button_24mm_hole_for_snapins();
+	}
+}
+
+solo_frame();

src/top-panel-solo-dir_arc-24mm-combined.scad

@@ -0,0 +1,28 @@
+/* Copyright Brian Stephan 2023
+ *
+ * This file is part of the Buildable Stick System.
+ *
+ * The Buildable Stick System 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.
+ *
+ * The Buildable Stick System 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
+ * the Buildable Stick System. If not, see <https://www.gnu.org/licenses/>.
+ */
+
+include <components.scad>
+
+module dir_arc_24mm_combined_6_button_panel() {
+	difference() {
+		rotate([0, 0, -90]) topplate_with_raised_overhang();
+		translate([-top_plate_x+105, -top_plate_y/2+135, 0]) dir_arc_24mm_combined_6_button();
+	}
+}
+
+dir_arc_24mm_combined_6_button_panel();