3d-stuff/openscad/foreign/sc808/io-shield.scad

// supermicro SC808 (and others) I/O-Shields to be able to utilize mITX-boards with extenation-cords that allow for Surface-Mounting
// by zeus - 2022-09-11 - CC-BY-NC-SA-4.0 - https://git.kostianix.de/zeus/3d-stuff/openscad/
// #####################################
// VARS:
// #####################################
mt=2;
q=0.01; //used as variable to remove manifold-glitches in preview. can be set to "0" in final version
$fn=100;
// shield:
shield_w=178; // let's hope that fits onto my delta...
shield_h=41;
shield_d=10; //around 11.5 in the original, but that is not needed
shield_tab_emboss_d=1; // that lowered lip, that the central and outer tabs mounts onto, 1mm (or one sheet-thickness) lower than the rest
shield_tab_emboss_l=22; // length of the above described cutouts
shield_tab_emboss_l2=shield_tab_emboss_l/2; // length of the side cutouts

shield_holes=1; // draw holes if >0. the perimeter-holes are manually placed, and should be disabled, if many vars get altered! (and then drilled manually)
shield_hole_d1=2.75;
shield_hole_d2=shield_hole_d1+0.5; // slightly conical holes for better inserting
// for separating the shield into two halves
shield_center_slot=1; // draw slot if >0
shield_center_slot_w=0.5;
shield_hole_center_dia=4; 
shield_hole_center_dist=shield_h/2;
// model "gril":
m_grill_w=3;
m_grill_h=shield_h*0.75-m_grill_w-2*mt;
m_grill_skew=25;
m_grill_offset=5;
m_grill_spacing=m_grill_w;
//port ethernet:
p_eth_hole_dist=27.5;
p_eth_hole_dia=4.5;
p_eth_slack=0.5;
p_eth_base_x=22+p_eth_slack;
p_eth_base_y=21.75+p_eth_slack;
p_eth_cut_x=16+p_eth_slack;
p_eth_cut_y=13.15+p_eth_slack;
p_eth_cut_z=mt;
p_eth_cut_x_offset=0;
p_eth_cut_y_offset=1.5;
//port usb:
p_usb_hole_dist=30;
p_usb_hole_dia=4.5;
p_usb_slack=0.5;
p_usb_base_x=23+p_eth_slack;
p_usb_base_y=16.5+p_eth_slack;
p_usb_cut_x=16+p_eth_slack;
p_usb_cut_y=15+p_eth_slack;
p_usb_cut_z=mt;
p_usb_cut_x_offset=0;
p_usb_cut_y_offset=0;
//port vga:
p_vga_hole_dist=25;
p_vga_hole_dia=4.5;
p_vga_slack=0.5;
p_vga_base_x=34+p_eth_slack;
p_vga_base_y=15.25+p_eth_slack;
p_vga_cut_x=15.75+p_eth_slack;
p_vga_cut_y=8+p_eth_slack;
p_vga_cut_z=mt;
p_vga_cut_x_offset=0;
p_vga_cut_y_offset=0;
//port slot:
p_slot_hole_dist=30;
p_slot_hole_dia=mt*3;
// #####################################
// MODEL:
// mounting holes around the shield perimeter
module port_ethernet(){
    cube([p_eth_base_x,p_eth_base_y,mt],center=true);
    translate([p_eth_cut_x_offset,p_eth_cut_y_offset,p_eth_cut_z+mt/2])cube([p_eth_cut_x,p_eth_cut_y,p_eth_cut_z+mt],center=true);
    hull(){
        translate([-p_eth_hole_dist/2,0,0])cylinder(d=p_eth_hole_dia+mt,h=mt,center=true);
        translate([p_eth_hole_dist/2,0,0])cylinder(d=p_eth_hole_dia+mt,h=mt,center=true);
   }
   translate([-p_eth_hole_dist/2,0,mt*1.5])cylinder(d=p_eth_hole_dia,h=mt*2,center=true);
   translate([p_eth_hole_dist/2,0,mt*1.5])cylinder(d=p_eth_hole_dia,h=mt*2,center=true);
}

module port_usb(){
    cube([p_usb_base_x,p_usb_base_y,mt],center=true);
    translate([p_usb_cut_x_offset,p_usb_cut_y_offset,p_usb_cut_z+mt/2])cube([p_usb_cut_x,p_usb_cut_y,p_usb_cut_z+mt],center=true);
    hull(){
        translate([-p_usb_hole_dist/2,0,0])cylinder(d=p_usb_hole_dia+mt,h=mt,center=true);
        translate([p_usb_hole_dist/2,0,0])cylinder(d=p_usb_hole_dia+mt,h=mt,center=true);
   }
   translate([-p_usb_hole_dist/2,0,mt*1.5])cylinder(d=p_usb_hole_dia,h=mt*2,center=true);
   translate([p_usb_hole_dist/2,0,mt*1.5])cylinder(d=p_usb_hole_dia,h=mt*2,center=true);
}

module port_vga(){
    cube([p_vga_base_x,p_vga_base_y,mt],center=true);
    translate([p_vga_cut_x_offset,p_vga_cut_y_offset,p_vga_cut_z+mt/2])cube([p_vga_cut_x,p_vga_cut_y,p_vga_cut_z+mt],center=true);
    hull(){
        translate([-p_vga_hole_dist/2,0,0])cylinder(d=p_vga_hole_dia+mt,h=mt,center=true);
        translate([p_vga_hole_dist/2,0,0])cylinder(d=p_vga_hole_dia+mt,h=mt,center=true);
   }
   translate([-p_vga_hole_dist/2,0,mt*1.5])cylinder(d=p_vga_hole_dia,h=mt*2,center=true);
   translate([p_vga_hole_dist/2,0,mt*1.5])cylinder(d=p_vga_hole_dia,h=mt*2,center=true);
}

module port_slot(){
    hull(){
        translate([-p_slot_hole_dist/2,0,mt])cylinder(d=p_slot_hole_dia,h=mt*2,center=true);
        translate([p_slot_hole_dist/2,0,mt])cylinder(d=p_slot_hole_dia,h=mt*2,center=true);
    }
}
module shield_hole(x,y,z,rotx,roty){
    translate([x,y,shield_d/2-z])rotate([rotx,roty,0])cylinder(d1=shield_hole_d1,d2=shield_hole_d2,h=mt+q,center=true);
}
// basic shield
module shield(){
    difference(){
        cube([shield_w,shield_h,shield_d],center=true); // basebox
        translate([0,0,mt/2+q])cube([shield_w-2*mt,shield_h-2*mt,shield_d-mt],center=true); // main hollowing
        for(x=[-shield_w/2+shield_tab_emboss_l/2,shield_w/2-shield_tab_emboss_l/2]){ 
            translate([x,shield_h/2-shield_tab_emboss_d/2,0])cube([shield_tab_emboss_l+q,shield_tab_emboss_d+q,shield_d+q],center=true);// top edge-cutout
        }
        for(x=[-shield_w/2+shield_tab_emboss_d/2,shield_w/2-shield_tab_emboss_d/2]){ 
            translate([x,shield_h/2-shield_tab_emboss_l2/2,0])cube([shield_tab_emboss_d+q,shield_tab_emboss_l2+q,shield_d+q],center=true);// side edge-cutout
        }

  }
        for(x=[-shield_w/2+shield_tab_emboss_l/2+mt,shield_w/2-shield_tab_emboss_l/2-mt]){ 
            translate([x,shield_h/2-shield_tab_emboss_d/2-mt,0])cube([shield_tab_emboss_l+mt+q,shield_tab_emboss_d+q,shield_d+q],center=true);// supportblock for top edge-cutout
        for(x=[-shield_w/2+shield_tab_emboss_d/2+shield_tab_emboss_d+mt/2,shield_w/2-shield_tab_emboss_d/2-shield_tab_emboss_d-mt/2]){ 
            translate([x,shield_h/2-shield_tab_emboss_l2/2-mt,0])cube([shield_tab_emboss_d+q,shield_tab_emboss_l2+q,shield_d+q],center=true);// supportblock for side edge-cutout
        }
    }
        cube([mt*4,shield_h,shield_d],center=true); // central support-block
}

// first iteration: optional slotting
module shield_1(){
  if (shield_center_slot>0) { // generate slot and matching connection-holes in the center
    difference(){
        shield();
        cube([shield_center_slot_w,shield_h+q,shield_d+q],center=true);
        for(y=[-shield_hole_center_dist/2,shield_hole_center_dist/2]){
            translate([0,y,mt/2])rotate([0,90,0])cylinder(d=shield_hole_center_dia,h=mt*4+q,center=true);
        }
    }
}
else shield();  
}

// second iteration: add some holes
module shield_2(){
    difference(){
        shield_1();
        if (shield_holes>0) {
            // some holes all around, (left, than clockwise, viewed from behind). THESE ARE MANUALLY PLACED!
            // shield_hole(x,y,z,rotx,roty), "z" is the distance from lip-edge to the center of the hole, x is from center
            shield_hole(-shield_w/2+mt/2,-0.5,4,0,-90); //left side
            shield_hole(-shield_w/2+mt/2+4.5,shield_h/2-shield_tab_emboss_d-mt/2-q*0.5,6.25,-90,0); //top side, 1st from left (recessed)
            shield_hole(-shield_w/2+mt/2+29.5,shield_h/2-mt/2,4.4,-90,0); //top side, 2nd from left 
            shield_hole(-shield_w/2+mt/2+147,shield_h/2-mt/2,4.4,-90,0); //top side, 3rd from left
            shield_hole(-shield_w/2+mt/2+162,shield_h/2-shield_tab_emboss_d-mt/2-q*0.5,5.5,-90,0); //top side, 4th from left (recessed)
            shield_hole(-shield_w/2+mt/2+171.5,shield_h/2-shield_tab_emboss_d-mt/2-q*0.5,6.25,-90,0); //top side, 5th from left (recessed)
            shield_hole(shield_w/2-mt/2,-0.5,4,0,90); //right side
            shield_hole(-shield_w/2+mt/2+172.5,-shield_h/2+mt/2,4.25,90,0); // bottom side, 1st one from right
            shield_hole(-shield_w/2+mt/2+56.25,-shield_h/2+mt/2,4.25,90,0); //bottom side, 2nd one from right
            shield_hole(-shield_w/2+mt/2+4.5,-shield_h/2+mt/2,4.25,90,0); //bottom side, 3rd one from right
        }
    }
}
// final interation: with fan-grills
module shield_grill(){
    difference(){
        shield_2(); 
        for(a=[0:m_grill_spacing*2:shield_w/2-mt*3-m_grill_offset*3]){
        translate([-shield_w/2+mt*3+m_grill_offset+a,0,-shield_d/2+mt/2+q]){
            hull(){
                for (y=[-m_grill_h/2,m_grill_h/2]){
                    rotate([0,0,-m_grill_skew])translate([0,y,0])cylinder(d=m_grill_w,h=2*mt,center=true);
                }
            }
            translate([shield_w/2,0,0])hull(){
                for (y=[-m_grill_h/2,m_grill_h/2]){
                    rotate([0,0,-m_grill_skew])translate([0,y,0])cylinder(d=m_grill_w,h=2*mt,center=true);
                }
            }
        }
    }
    }
}
// final iteration: with ports (manual placement)
module shield_ports(){
    difference(){
        shield_2();
        translate([-75,-1,-3*mt-q])rotate([0,0,-90])#port_ethernet();
        translate([-37.5,-1,-3*mt-q])rotate([0,0,-90])#port_ethernet();
        translate([22.5,-1,-3*mt-q])rotate([0,0,-90])#port_ethernet();
        translate([50,0,-3*mt-q])rotate([0,0,-90])#port_usb();
//flipped and embossed so that only 1mm of the plate thickness is left, due to the way, d-sub is mounted, and no support is needed for printing
        translate([75,-1,-mt-(mt-1)])rotate([180,0,-90])port_vga(); 
        // slots
        for (x=[-60,-52.5,-22.5,-15,-7.5,7.5,37.5,62.5]){
            translate([x,0,-3*mt-q])rotate([0,0,90])#port_slot();
        }
    }
}
// #####################################
// DRAWING:

//    shield_2();

//port_ethernet();
shield_ports();


// todo: add text