fix an issue with frame wall + small button screw-in space

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

CHANGELOG.md

@@ -2,6 +2,35 @@
 
 Included is a summary of changes to the project, by version. Details can be found in the commit history.
 
+## v4.4.2
+
+### Bugfixes
+
+* Fix a regression with the small button screw-in space cutting into the frame wall supports. The screw-in space is
+  potentially more important for some nuts than the thickness of the frame wall supports, so the latter have been
+  thinned slightly.
+
+## v4.4.1
+
+### Features
+
+* A new lever + Sega 2P 6 button panel has been added. The overhang version hadn't been updated in forever, but the
+  inset panel moved stuff around in a way that allowed a couple aux buttons to fit in, so those have been added to the
+  overhang panel as well.
+* A horizontal stripe frame windowed piece has been added. YMMV may vary a bit on this vs. an empty window --- you can
+  see less of the inner object with the stripes, but it's a bit more stable.
+
+### Improvements
+
+* The frame wall slashes have been made a bit more reusable.
+* The area around button holes for screw-ins has been tweaked to be a bit smaller for 30mm buttons and a bit larger for
+  24mm buttons.
+
+### Miscellaneous
+
+* A bottom overhang panel was positioned incorrectly in the demo file; this has been fixed.
+* Added a demo of the one-panel overhang lever + 6 button stick.
+
 ## v4.4.0
 
 ### Features

Makefile

@@ -1,7 +1,8 @@
 all:
 	python build.py
 	mkdir -p ./build/docs
-	cp ./docs/README-objects.md ./build/README.md
+	cp ./README.md ./build/README.md
+	cp ./docs/README-objects.md ./build/README-objects.md
 	cp ./docs/assembly-and-tips.md ./build/docs/assembly-and-tips.md
 	cp ./docs/printing-and-materials.md ./build/docs/printing-and-materials.md
 	cp ./LICENSE ./build/LICENSE

README.md

@@ -67,6 +67,9 @@ about what the types of parts are and how to use them:
     * Various experiments and things not directly related to making an arcade stick. At time of writing, there's a
       couple pieces for a little stand for the stick, solely for vanity purposes.
 
+Feel free to request or contribute to more objects. Additional documentation regarding assembling the stick is available
+in `docs/assembly-and-tips.md`.
+
 ## Printing
 
 These items all fit on a 256mm^2 print bed; I use a Bambu Lab P1P based on what I've learned from the
@@ -161,12 +164,13 @@ to hang out and discuss issues and features and whatnot.
 
 Written by and copyright Brian S. Stephan (<bss@incorporeal.org>).
 
-The Buildable Stick System is free software: you can redistribute it and/or modify it under the terms of the GNU General Public
+The Buildable Stick System is free software: you can redistribute it and/or modify it under the terms of the GNU General
-License as published by the Free Software Foundation, either version 3 of the License, or (at your option) any later
+Public License as published by the Free Software Foundation, either version 3 of the License, or (at your option) any
-version.
+later version.
 
-The Buildable Stick System is distributed in the hope that it will be useful, but WITHOUT ANY WARRANTY; without even the implied
+The Buildable Stick System is distributed in the hope that it will be useful, but WITHOUT ANY WARRANTY; without even the
-warranty of MERCHANTABILITY or FITNESS FOR A PARTICULAR PURPOSE. See the GNU General Public License for more details.
+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/>.

TODO.md

@@ -5,3 +5,7 @@ Notes for "next time".
 ## v4.x
 
 * Engraving some cosmetic stuff? Or maybe a place to mount other plates on the top?
+
+## v5
+
+* Finishing the build123d rewrite?

demo/all-together-demo-solo.scad

@@ -0,0 +1,28 @@
+/*
+ * SPDX-FileCopyrightText: © 2023 Brian S. Stephan <bss@incorporeal.org>
+ * SPDX-License-Identifier: GPL-3.0-or-later
+ */
+
+include <parameters.scad>
+include <components.scad>
+use <frames/pieces/extended/front-or-back.scad>
+use <frames/pieces/extended/side-extended-to-bottom.scad>
+use <frames/pieces/extended/front-or-back-clean-for-extended-side-aux-and-neutrik.scad>
+use <panels/inset/lever-and-dir_arc-plus-w-30mm-panel.scad>
+use <panels/inset/lever-and-sega-2p-6-button-panel-with-aux-with-mount.scad>
+use <misc/dustwasher-jlf.scad>
+
+top_panel_color        = "#5B6579";
+bottom_panel_color     = "#8E9089";
+frame_top_bottom_color = "#8E9089";
+frame_side_color       = "#8E9089";
+top_deco_color         = "#000000";
+
+color(top_panel_color) translate([0, 0, frame_z/2-panel_z+0.01]) lever_and_sega_2p_6_button_panel_with_aux_with_mount();
+color(frame_side_color) translate([0, 0, -2.5]) extra_extended_left_or_right_frame_piece();
+color(frame_side_color) translate([0, 0, -2.5]) mirror([1, 0, 0]) extra_extended_left_or_right_frame_piece();
+color(frame_top_bottom_color) translate([0, 0, -2.5])  extended_front_or_back_frame_piece();
+color(frame_top_bottom_color) translate([0, 0, -2.5]) rotate([180, 0, 0]) front_or_back_aux_and_neutrik_box_frame_piece_for_extended_side();
+color(bottom_panel_color) translate([0, 0, -5-frame_z/2+5]) panel();
+
+color(top_deco_color) translate([-65, 5, 3+frame_z/2-panel_z]) jlf_dustwasher();

demo/blown-up-demo.scad

@@ -26,7 +26,8 @@ color("black") rotate([180, 0, 0]) translate([-frame_x/2+5-25, -55, -2.5]) front
 color("black") rotate([180, 0, 0]) rotate([0, 180, 0]) translate([-frame_x/2+5-25, -55, -2.5]) front_or_back_aux_and_neutrik_box_frame_piece();
 color("black") rotate([0, 180, 0]) interconnect_frame_piece();
 color("#C12E1F") translate([-panel_x/2-25, 0, -5-frame_z/2-75]) left_or_right_overhang_panel();
-color("#C12E1F") mirror([0, 1, 0]) translate([panel_x/2+25, 0, -5-frame_z/2-75]) left_or_right_overhang_panel();
+color("#C12E1F") mirror([0, 1, 0]) translate([panel_x/2+25, 0, -5-frame_z/2-75]) rotate([0, 0, 180])
+	left_or_right_overhang_panel();
 
 color("black") translate([0, 0, 3+frame_z/2+150]) dir_arc_plus_w_30mm_and_sega_2p_plus_one_decorative_plate();
 color("black") translate([-195, 25, 3+frame_z/2+150]) lsx_nobi_dustwasher();

docs/README-objects.md

@@ -1,54 +1,11 @@
 # The Buildable Stick System
 
-Files for 3D printing an arcade stick.
+Files for 3D printing an arcade stick. See `README.md` for the core documentation, this file is specific to distributed
+objects.
 
-## Objects
+## Attribution
 
-The following notes document the objects in the Buildable Stick System and how you can use them:
+### Author and Licensing
-
-* `frames/`
-    * `complete/` --- these are the four walls of the frame as one piece, in a couple variations for combining into
-      larger arcade sticks. They are simple to assemble, but you have fewer modularity/customization options, and they
-      are harder to print because the physics of the material cooling will probably pull the corners up. They also need
-      supports, since the top and bottom of the frame both have trays for panels to go into. Use at your own risk.
-    * `pieces/`
-        * `box/` --- these are the same four walls (generally speaking) as in the complete frames above, broken out into
-          modular pieces to print separately. Because they are separate pieces, you can mix and match colors, and you
-          can lay them all face down on the print surface for better adhesion and surface patterns. There are also
-          variants here, the "windowed" pieces, for doing two-tone variants and that kind of thing.
-        * `extended/` --- the frame walls are pulled out to create MCZ TE-style extended sides. Rather than getting a
-          box look, you get a longer slab with nice bevels. These look nice, but slightly fiddily to print (and of
-          course need more material) --- watch your surface adhesion.
-        * `interconnect` --- complete frames are bolted to one another, but for frame pieces, there is an interconnect
-          that stands in for the joined inner wall. You need this if you are combining multiple sets of walls, e.g. for
-          a two-panel-long stick.
-* `panels/`
-    * `inset/` --- various panels, all of the same size, that fit into and flush with the frame, making the arcade stick
-      top or bottom. These work equally well with box or extended frames, and aside from using up a bit of the space
-      inside the frame, come with no downsides --- they print easily and are a pretty simple shape to tweak and remix.
-    * `overhang/` --- overhang panels have their plane extending over the edge of the frame, creating a bit of a
-      sandwich look. This is mostly an aesthetic choice, but they sit higher in the frame as well, the main panel being
-      over/under the frame rather than within it. This extra space is useful for taller levers. The only downside to
-      these is that they aren't as reusable as the inset panels, since the inset panels can go anywhere, but the
-      overhang panels must be designed to not overlap with other overhang panels, so you might have to make more custom
-      variants depending on where you put things.
-* `misc/`
-    * Pieces that I haven't organized better (yet) --- there are decorative plates for top buttons and similar to give
-      more color variance and some layers to the arcade stick, some very simple dustwashers, plates that fit rocker
-      switches and the like in Neutrik D or 20mm holes, and a lever mount spacer for getting your lever shaft at the
-      desired height. You don't *need* any of these, but you'll probably use a few.
-* `extras/`
-    * Various experiments and things not directly related to making an arcade stick. At time of writing, there's a
-      couple pieces for a little stand for the stick, solely for vanity purposes.
-
-Feel free to request or contribute to more objects, see the links to Git repos below.
-
-## Printing and Assembling
-
-Additional documentation regarding printing the objects and assembling the stick are available in
-`docs/printing-and-materials.md` and `docs/assembly-and-tips.md`, respectively.
-
-## Author and Licensing
 
 Written by and copyright Brian S. Stephan (<bss@incorporeal.org>).
 
@@ -71,9 +28,13 @@ 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/>.
 
-## Lineage
+### Distributing BSS Sticks
 
-Inspired by the incredible work of [TheTrain](https://github.com/TheTrainGoes) on the [OpenStickCommunity Fightstick
+Under the terms of the GPLv3, you must inform the receiver of the "object code" of their rights under the GPLv3. This is
-Case](https://github.com/OpenStickCommunity/Hardware/tree/main/Fightstick%20Case), itself based on the incredible work
+a bit of a gray area for physical objects, but likely applies to distribution of modified or unmodified STL, STEP, etc.
-by [Dash n'Mash](https://twitter.com/Dash_xx_Mash?s=20). Original work Copyright 2023 TheTrain, [licensed under CC BY
+files at a minimum. The easiest way to satisfy the GPLv3 in either situation is to provide a link to the source code
-4.0](https://creativecommons.org/licenses/by/4.0/).
+(either the unmodified mainline project, or your copy, with modifications listed in a "prominent notice"); something
+like the below should suffice in either electronic or printed form:
+
+> This arcade stick is part of the Buildable Stick System, version X.Y.Z; the source code to this program is available
+> under the terms of the GNU General Public License, at [LINK].

src/components.scad

@@ -28,10 +28,9 @@ module panel_holes() {
 // for snap-ins, etc.
 module button_24mm_hole() {
 	cylinder(r=small_button_radius, h=100, $fn=50, center=true);
-	// carve out space for snap-ins, leave 3mm
+	// carve out space for snap-ins and screw-in nuts
-	// slagcoin has screw-in nut diameter at 29.5mm, so radius+3 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+3, h=49, $fn=50, center=true);
+	translate([0, 0, -25]) cylinder(r=small_button_radius+button_radius_connector_space, h=49, $fn=50, center=true);
 	// space for decorative button surround stuff
 	translate([0, 0, 50]) cylinder(r=small_button_radius*decorative_radius_scale, h=20, $fn=50, center=true);
 	translate([0, 0, 70]) cylinder(r=small_button_radius*jumbo_decorative_radius_scale, h=20, $fn=50, center=true);
@@ -41,10 +40,9 @@ module button_24mm_hole() {
 // for snap-ins, etc.
 module button_30mm_hole() {
 	cylinder(r=big_button_radius, h=100, $fn=50, center=true);
-	// carve out space for snap-ins, leave 3mm
+	// carve out space for snap-ins and screw-in nuts
-	// 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);
+	translate([0, 0, -25]) cylinder(r=big_button_radius+button_radius_connector_space, h=49, $fn=50, center=true);
 	// space for decorative button surround stuff
 	translate([0, 0, 50]) cylinder(r=big_button_radius*decorative_radius_scale, h=20, $fn=50, center=true);
 	translate([0, 0, 70]) cylinder(r=big_button_radius*jumbo_decorative_radius_scale, h=20, $fn=50, center=true);
@@ -82,7 +80,7 @@ module rocker_20mm_mount() {
 // space for a neutrik D mount or 24mm button --- Z is meant to leave some lip now that frames
 // are primarily printed on their side
 module frame_cutout() {
-	cube([30.5, 8, frame_z-(panel_z*3)], center=true);
+	cube([35, 8, frame_z-(panel_z*3)], center=true);
 }
 
 // bank of three 24mm buttons, commonly on a frame face
@@ -339,6 +337,22 @@ module frame() {
 	}
 }
 
+/* MISC SHAPES --- for cutting out decorative panels, frame wall windows, etc. */
+
+// for cutting out slashes from the frame outer wall
+module slash_cutout() {
+	polyhedron([
+		[slash_inner_displacement/2, -frame_wall/2, -slash_height/2],
+		[(slash_inner_displacement/2+slash_width), -frame_wall/2, -slash_height/2],
+		[(slash_inner_displacement/2+slash_width), frame_wall/2, -slash_height/2],
+		[slash_inner_displacement/2, frame_wall/2, -slash_height/2],
+		[-(slash_inner_displacement/2+slash_width), -frame_wall/2, slash_height/2],
+		[-slash_inner_displacement/2, -frame_wall/2, slash_height/2],
+		[-slash_inner_displacement/2, frame_wall/2, slash_height/2],
+		[-(slash_inner_displacement/2+slash_width), frame_wall/2, slash_height/2]
+	], [[0, 1, 2, 3], [4, 5, 1, 0], [7, 6, 5, 4], [5, 6, 2, 1], [6, 7, 3, 2], [7, 4, 0, 3]]);
+}
+
 /* LAYOUTS */
 
 // Directional Arc (both hands)

src/frames/pieces/box/front-or-back-windowed-backslashes.scad

@@ -8,23 +8,14 @@ include <components.scad>
 use <front-or-back.scad>
 use <front-or-back-inner-wall.scad>
 
-module backslash() {
-	polyhedron([[5, -frame_y/2, -(frame_z-panel_z*3)/2], [20, -frame_y/2, -(frame_z-panel_z*3)/2],
-			[20, -frame_y/2+frame_wall, -(frame_z-panel_z*3)/2], [5, -frame_y/2+frame_wall, -(frame_z-panel_z*3)/2],
-			[-20, -frame_y/2, (frame_z-panel_z*3)/2], [-5, -frame_y/2, (frame_z-panel_z*3)/2],
-			[-5, -frame_y/2+frame_wall, (frame_z-panel_z*3)/2], [-20, -frame_y/2+frame_wall, (frame_z-panel_z*3)/2]],
-		[[0, 1, 2, 3], [4, 5, 1, 0], [7, 6, 5, 4], [5, 6, 2, 1], [6, 7, 3, 2], [7, 4, 0, 3]]
-	);
-}
-
 module backslashes() {
-	translate([-60, 0, 0]) backslash();
+	translate([-60, -(frame_y-frame_wall)/2, 0]) slash_cutout();
-	translate([-40, 0, 0]) backslash();
+	translate([-40, -(frame_y-frame_wall)/2, 0]) slash_cutout();
-	translate([-20, 0, 0]) backslash();
+	translate([-20, -(frame_y-frame_wall)/2, 0]) slash_cutout();
-	backslash();
+	translate([0, -(frame_y-frame_wall)/2, 0]) slash_cutout();
-	translate([20, 0, 0]) backslash();
+	translate([20, -(frame_y-frame_wall)/2, 0]) slash_cutout();
-	translate([40, 0, 0]) backslash();
+	translate([40, -(frame_y-frame_wall)/2, 0]) slash_cutout();
-	translate([60, 0, 0]) backslash();
+	translate([60, -(frame_y-frame_wall)/2, 0]) slash_cutout();
 }
 
 module backslashes_windowed_front_or_back_box_frame_piece() {

src/frames/pieces/box/front-or-back-windowed-horiz-stripes.scad

@@ -0,0 +1,29 @@
+/*
+ * SPDX-FileCopyrightText: © 2024 Brian S. Stephan <bss@incorporeal.org>
+ * SPDX-License-Identifier: GPL-3.0-or-later
+ */
+
+include <parameters.scad>
+include <components.scad>
+use <front-or-back.scad>
+use <front-or-back-inner-wall.scad>
+
+module front_stripe() {
+	cube([frame_x-(frame_mount_column_width*1.75)*2, frame_wall, 6], center=true);
+}
+
+module windowed_front_or_back_box_frame_piece() {
+	difference() {
+		front_or_back_box_frame_piece();
+		// subtract frame wall windows
+		translate([0, -(frame_y-frame_wall)/2, 18]) front_stripe();
+		translate([0, -(frame_y-frame_wall)/2, 9]) front_stripe();
+		translate([0, -(frame_y-frame_wall)/2, 0]) front_stripe();
+		translate([0, -(frame_y-frame_wall)/2, -9]) front_stripe();
+		translate([0, -(frame_y-frame_wall)/2, -18]) front_stripe();
+		// subtract the inner wall area that will be provided by the other piece
+		front_or_back_inner_wall_frame_piece();
+	}
+}
+
+windowed_front_or_back_box_frame_piece();

src/frames/pieces/box/side-windowed-backslashes.scad

@@ -8,21 +8,12 @@ include <components.scad>
 use <side.scad>
 use <side-inner-wall.scad>
 
-module backslash() {
-	polyhedron([[-frame_x/2, -5, -(frame_z-panel_z*3)/2], [-frame_x/2, -20, -(frame_z-panel_z*3)/2],
-			[-frame_x/2+frame_wall, -20, -(frame_z-panel_z*3)/2], [-frame_x/2+frame_wall, -5, -(frame_z-panel_z*3)/2],
-			[-frame_x/2, 20, (frame_z-panel_z*3)/2], [-frame_x/2, 5, (frame_z-panel_z*3)/2],
-			[-frame_x/2+frame_wall, 5, (frame_z-panel_z*3)/2], [-frame_x/2+frame_wall, 20, (frame_z-panel_z*3)/2]],
-		[[0, 1, 2, 3], [4, 5, 1, 0], [7, 6, 5, 4], [5, 6, 2, 1], [6, 7, 3, 2], [7, 4, 0, 3]]
-	);
-}
-
 module backslashes() {
-	translate([0, -40, 0]) backslash();
+	translate([-(frame_x-frame_wall)/2, -40, 0]) rotate([0, 0, -90]) slash_cutout();
-	translate([0, -20, 0]) backslash();
+	translate([-(frame_x-frame_wall)/2, -20, 0]) rotate([0, 0, -90]) slash_cutout();
-	backslash();
+	translate([-(frame_x-frame_wall)/2, 0, 0]) rotate([0, 0, -90]) slash_cutout();
-	translate([0, 20, 0]) backslash();
+	translate([-(frame_x-frame_wall)/2, 20, 0]) rotate([0, 0, -90]) slash_cutout();
-	translate([0, 40, 0]) backslash();
+	translate([-(frame_x-frame_wall)/2, 40, 0]) rotate([0, 0, -90]) slash_cutout();
 }
 
 module backslashes_windowed_side_box_frame_piece() {

src/frames/pieces/box/side-windowed-horiz-stripes.scad

@@ -0,0 +1,29 @@
+/*
+ * SPDX-FileCopyrightText: © 2024 Brian S. Stephan <bss@incorporeal.org>
+ * SPDX-License-Identifier: GPL-3.0-or-later
+ */
+
+include <parameters.scad>
+include <components.scad>
+use <side.scad>
+use <side-inner-wall.scad>
+
+module side_stripe() {
+	cube([frame_wall, frame_y-(frame_mount_column_width*1.75)*2, 6], center=true);
+}
+
+module windowed_side_box_frame_piece() {
+	difference() {
+		side_box_frame_piece();
+		// subtract frame wall windows
+		translate([-(frame_x-frame_wall)/2, 0, 18]) side_stripe();
+		translate([-(frame_x-frame_wall)/2, 0, 9]) side_stripe();
+		translate([-(frame_x-frame_wall)/2, 0, 0]) side_stripe();
+		translate([-(frame_x-frame_wall)/2, 0, -9]) side_stripe();
+		translate([-(frame_x-frame_wall)/2, 0, -18]) side_stripe();
+		// subtract the inner wall area that will be provided by the other piece
+		side_inner_wall_frame_piece();
+	}
+}
+
+windowed_side_box_frame_piece();

src/panels/inset/lever-and-sega-2p-6-button-panel-with-aux-with-mount.scad

@@ -0,0 +1,25 @@
+/*
+ * SPDX-FileCopyrightText: © 2023 Brian S. Stephan <bss@incorporeal.org>
+ * SPDX-License-Identifier: GPL-3.0-or-later
+ */
+
+include <parameters.scad>
+include <components.scad>
+
+module lever_and_sega_2p_6_button_panel_with_aux_with_mount() {
+	difference() {
+		union() {
+			panel();
+			translate([45, -58, -panel_z/2]) rotate([0, 0, 13]) pcb_mount();
+		}
+		translate([90, -25, 0]) sega_2p_6_button();
+		translate([-65, 5, 0]) union() {
+			levermountholes();
+			levermountcountersinks();
+		}
+		translate([17, 70, 0]) button_24mm_hole();
+		translate([-17, 70, 0]) button_24mm_hole();
+	}
+}
+
+lever_and_sega_2p_6_button_panel_with_aux_with_mount();

src/panels/overhang/solo-lever-and-sega-2p-6-button-panel-with-aux-with-mount.scad

@@ -8,13 +8,17 @@ include <components.scad>
 
 module lever_and_sega_2p_6_button_solo_overhang_panel() {
 	difference() {
-		// base plate
 		union() {
 			panel_with_raised_overhang();
-			translate([-60, 18, -((panel_z/2)+(lever_mount_z/2))]) levermountbase();
+			translate([45, -58, -panel_z/2]) rotate([0, 0, 13]) pcb_mount();
 		}
-		translate([95, -20, 0]) sega_2p_6_button();
+		translate([90, -25, 0]) sega_2p_6_button();
-		translate([-60, 18, 0]) levermountholes();
+		translate([-65, 5, 0]) union() {
+			levermountholes();
+			levermountcountersinks();
+		}
+		translate([17, 70, 0]) button_24mm_hole();
+		translate([-17, 70, 0]) button_24mm_hole();
 	}
 }
 

src/parameters.scad

@@ -23,6 +23,11 @@ small_button_radius = 12 + hole_tolerance;
 // 30mm button
 big_button_radius = 15 + hole_tolerance;
 
+// carve out space around buttons for screw-in nuts
+// slagcoin has screw-in nut diameter at 36mm for 30mm buttons, 29.5 for 24mm buttons
+// radius + value below should leave space for the nut and for fingers to grab the nut
+button_radius_connector_space = 5;
+
 // JLF mount dimensions
 lever_mount_x = 53;
 lever_mount_y = 95;
@@ -89,3 +94,8 @@ neutrik_d_radius = 12 + hole_tolerance;
 // additional button radius for decorative panels, etc.
 decorative_radius_scale = 1.75;
 jumbo_decorative_radius_scale = 2;
+
+// decorative slash parameters
+slash_inner_displacement = 10;
+slash_width = 15;
+slash_height = frame_z-panel_z*3;