3dmodels/sonoff_dev_housing.jscad

// title      : Sonoff DEV box for lamp post
// author     : Knut Ahlers
// license    : MIT License
// revision   : 0.1
// file       : sonoff_dev_lamp.jscad

// All measurements in mm
const innerSpace = 15 // free room on the inside from the board not to bend the cables that hard
const innerSpaceHeight = 30
const boardSize = 50 // 50x50mm
const boardSupportHeight = 10 // 10mm pins to put the board on
const boardSupportRadius = 1 // 2mm (holes do have 3mm)
const boardSupportEdgeDist = 2.5 // 2.5mm from the edges
const lampPostRadius = 7.5 // 15mm diameter
const lampPostSupport = lampPostRadius + 4.5 // adjust for proper grip
const screwBaseSize = 3 // block to screw the screw into
const screwHeadRadius = 1.25 // screw head diameter = 2*screwHeadRadius
const screwDiameter = 0.4 // diameter for the hole the screw is screwed into
const wall = 2.5 // wall thickness

function main() {
	const boardSupport = cylinder({
		h: boardSupportHeight + wall,
		r: boardSupportRadius,
		center: true,
	})

	const screwHeadSink = sphere({
		r: screwHeadRadius,
		center: true,
	})

	const screwHole = cylinder({
		h: screwBaseSize,
		r: screwDiameter,
		center: true,
	})

	const screwBase = difference(
		cube({ size: [screwBaseSize, screwBaseSize, screwBaseSize], center: true }),
		screwHole
	)

	return [
		// Housing without lid
		union(
			// Housing with holder
			difference(
				union(
					// Main housing block
					cube({ size: [
						boardSize + innerSpace + wall,
						boardSize + innerSpace + wall,
						innerSpaceHeight + wall,
					], center: true }),
					// Lamp post holder
					difference(
						cylinder({
							h: boardSize + innerSpace + wall,
							r: lampPostSupport,
							center: true,
							resolution: 100,
						}),
						cylinder({
							h: boardSize + innerSpace + wall,
							r: lampPostRadius,
							center: true,
							resolution: 100,
						}).translate([-7.5, 0, 0])
					)
					.rotateY(90)
					.translate([0, 0, (innerSpaceHeight + wall)/2])
				),
				// Inner housing
				cube({ size: [
					boardSize + innerSpace,
					boardSize + innerSpace,
					innerSpaceHeight,
				], center: true }).translate([0, 0, wall * -1])
			),

			// Board supports
			translate([
				boardSize / 2 - boardSupportEdgeDist,
				boardSize / 2 - boardSupportEdgeDist,
				(innerSpaceHeight + wall) / 2 - (boardSupportHeight + wall) / 2,
			], boardSupport),
			translate([
				(boardSize / 2 - boardSupportEdgeDist) * -1,
				boardSize / 2 - boardSupportEdgeDist,
				(innerSpaceHeight + wall) / 2 - (boardSupportHeight + wall) / 2,
			], boardSupport),
			translate([
				boardSize / 2 - boardSupportEdgeDist,
				(boardSize / 2 - boardSupportEdgeDist) * -1,
				(innerSpaceHeight + wall) / 2 - (boardSupportHeight + wall) / 2,
			], boardSupport),
			translate([
				(boardSize / 2 - boardSupportEdgeDist) * -1,
				(boardSize / 2 - boardSupportEdgeDist) * -1,
				(innerSpaceHeight + wall) / 2 - (boardSupportHeight + wall) / 2,
			], boardSupport),

			// Screw bases
			translate([
				(boardSize + innerSpace) / 2 - screwBaseSize / 2,
				(boardSize + innerSpace) / 2 - screwBaseSize / 2,
				((innerSpaceHeight + wall) / 2 - screwBaseSize / 2) * -1,
			], screwBase),
			translate([
				((boardSize + innerSpace) / 2 - screwBaseSize / 2) * -1,
				(boardSize + innerSpace) / 2 - screwBaseSize / 2,
				((innerSpaceHeight + wall) / 2 - screwBaseSize / 2) * -1,
			], screwBase),
			translate([
				(boardSize + innerSpace) / 2 - screwBaseSize / 2,
				((boardSize + innerSpace) / 2 - screwBaseSize / 2) * -1,
				((innerSpaceHeight + wall) / 2 - screwBaseSize / 2) * -1,
			], screwBase),
			translate([
				((boardSize + innerSpace) / 2 - screwBaseSize / 2) * -1,
				((boardSize + innerSpace) / 2 - screwBaseSize / 2) * -1,
				((innerSpaceHeight + wall) / 2 - screwBaseSize / 2) * -1,
			], screwBase)
		).translate([(boardSize + innerSpace + wall + 5) * -0.5, 0, (innerSpaceHeight + wall)/2]),

		// Lid
		difference(
			cube({ size: [
				boardSize + innerSpace + wall,
				boardSize + innerSpace + wall,
				wall,
			], center: true }),

			// Screw holes
			translate([
				(boardSize + innerSpace) / 2 - screwBaseSize / 2,
				(boardSize + innerSpace) / 2 - screwBaseSize / 2,
				0,
			], screwHole),
			translate([
				((boardSize + innerSpace) / 2 - screwBaseSize / 2) * -1,
				(boardSize + innerSpace) / 2 - screwBaseSize / 2,
				0,
			], screwHole),
			translate([
				(boardSize + innerSpace) / 2 - screwBaseSize / 2,
				((boardSize + innerSpace) / 2 - screwBaseSize / 2) * -1,
				0,
			], screwHole),
			translate([
				((boardSize + innerSpace) / 2 - screwBaseSize / 2) * -1,
				((boardSize + innerSpace) / 2 - screwBaseSize / 2) * -1,
				0,
			], screwHole),

			// Screw head sinks
			translate([
				(boardSize + innerSpace) / 2 - screwBaseSize / 2,
				(boardSize + innerSpace) / 2 - screwBaseSize / 2,
				screwHeadRadius - wall / 3,
			], screwHeadSink),
			translate([
				((boardSize + innerSpace) / 2 - screwBaseSize / 2) * -1,
				(boardSize + innerSpace) / 2 - screwBaseSize / 2,
				screwHeadRadius - wall / 3,
			], screwHeadSink),
			translate([
				(boardSize + innerSpace) / 2 - screwBaseSize / 2,
				((boardSize + innerSpace) / 2 - screwBaseSize / 2) * -1,
				screwHeadRadius - wall / 3,
			], screwHeadSink),
			translate([
				((boardSize + innerSpace) / 2 - screwBaseSize / 2) * -1,
				((boardSize + innerSpace) / 2 - screwBaseSize / 2) * -1,
				screwHeadRadius - wall / 3,
			], screwHeadSink)
		).translate([(boardSize + innerSpace + wall + 5) * 0.5, 0, wall/2])
	]
}

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