add roundedcube.scad, first pass at additional port access points in case

roundedcube.scad

@@ -0,0 +1,61 @@
+// Higher definition curves
+$fs = 0.01;
+
+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;
+
+	module build_point(type = "sphere", rotate = [0, 0, 0]) {
+		if (type == "sphere") {
+			sphere(r = radius);
+		} else if (type == "cylinder") {
+			rotate(a = rotate)
+			cylinder(h = diameter, r = radius, center = true);
+		}
+	}
+
+	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")
+						) {
+							build_point("sphere");
+						} 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]
+							);
+							build_point("cylinder", rotate);
+						}
+					}
+				}
+			}
+		}
+	}
+}

soundslab_10000_v1.scad

@@ -8,24 +8,38 @@ include <roundedcube.scad>
 // parameters - all lengths in mm
 battery_width  = 60;
 battery_length = 102;
-battery_depth  = 13;
+battery_depth  = 19; // battery + UPS HAT + external USB-A port
 
-depth_of_circuit_boards = 6; // includes tallest component
+pi_width  = 64; 
+pi_length = 30;
+pi_height = 13; // pi zero w and Pirate Audio Headphone Amp HAT stacked
 
 lcd_width  = 23.4;
 lcd_height = 23.4;
 lcd_depth  = 6; // how far to recess from top surface of case
 
+headphone_offset_length = 20; // from "top"
+headphone_offset_depth  = 5;  // from "front"
+
+usb_a_offset_length = 15;  // from "bottom"
+usb_a_offset_depth  = 11;  // from "back"
+
+micro_usb_offset_width = 18; // from "right"
+micro_usb_offset_depth = 11; // from "back"
+
 // build
+case_width  = pi_width + 2;                       // wider of battery_width and pi_width
+case_length = battery_length + pi_length + 2 + 2; // extra 2mm for space between battery and pi
+case_depth  = battery_depth + 2;                  // deeper of battery_depth and pi_depth
 
 difference() {
     // case
     color("white", 0.4) {
         roundedcube(
             [
-                battery_width + 1, 
+                case_width,  
-                battery_length + 1,
+                case_length, 
-                depth_of_circuit_boards + battery_depth + 2
+                case_depth   
             ],
             false,
             5
@@ -36,9 +50,9 @@ difference() {
         color("white", 0.0) {
             roundedcube(
                 [
-                    battery_width - 1,
+                    case_width  - 2,
-                    battery_length - 1,
+                    case_length - 2,
-                    depth_of_circuit_boards + battery_depth
+                    case_depth  - 2
                 ],
                 false,
                 5
@@ -49,9 +63,9 @@ difference() {
     // active area of the LCD screen is 23.4mm x 23.4mm according to http://www.lcdwiki.com/1.3inch_IPS_Module
     // lcd cutout
     translate ([
-        ((battery_width + 1) / 2) + 8 - (lcd_width / 2),
+        (case_width / 2) + 8 - (lcd_width / 2),
-        ((battery_length + 1) - 10) - (lcd_height),
+        (case_length - 10) - (lcd_height),
-        battery_depth + 6
+        case_depth - 6
     ]) {
         color ("blue") {
             cube(
@@ -63,9 +77,9 @@ difference() {
     
     // lcd buttons
     translate ([
-        ((battery_width + 1) / 2) + 21,
+        (case_width / 2) + 21,
-        ((battery_length + 1) - 18),
+        (case_length - 18),
-        battery_depth + 6
+        case_depth - 6
     ]) {
         color ("green") {
             cube(
@@ -76,9 +90,9 @@ difference() {
     }
     
     translate ([
-        ((battery_width + 1) / 2) + 21,
+        (case_width / 2) + 21,
-        ((battery_length + 1) - 28),
+        (case_length - 28),
-        battery_depth + 6
+        case_depth - 6
     ]) {
         color ("green") {
             cube(
@@ -89,9 +103,9 @@ difference() {
     }
     
     translate ([
-        ((battery_width + 1) / 2) - 8,
+        (case_width / 2) - 8,
-        ((battery_length + 1) - 18),
+        (case_length - 18),
-        battery_depth + 6
+        case_depth - 6
     ]) {
         color ("green") {
             cube(
@@ -102,9 +116,9 @@ difference() {
     }
     
     translate ([
-        ((battery_width + 1) / 2) - 8,
+        (case_width / 2) - 8,
-        ((battery_length + 1) - 28),
+        (case_length - 28),
-        battery_depth + 6
+        case_depth - 6
     ]) {
         color ("green") {
             cube(
@@ -116,9 +130,9 @@ difference() {
     
     // joystick
     translate ([
-        ((battery_width + 1) / 2) - 17,
+        (case_width / 2) - 17,
-        ((battery_length + 1) - 27.5),
+        (case_length - 27.5),
-        battery_depth + 6
+        case_depth - 6
     ]) {
         rotate(a=45,v=[0,0,1]) {
             color ("green") {
@@ -130,4 +144,47 @@ difference() {
         }
     }
     
+    // headphone jack
+    translate([
+        -1,                                    // start far left of device
+        case_length - headphone_offset_length, // distance from "top"
+        case_depth  - headphone_offset_depth   // distance from "front"
+    ]) {
+        rotate(a=90,v=[0,1,0]) {
+            color ("yellow") {
+                    cylinder(
+                        h=3,
+                        d=4
+                    );
+            }
+        }
+    }
+    
+    // usb-a port (external storage)
+    translate([
+        -1,                             // start far left of device
+        usb_a_offset_length,            // distance from "bottom"
+        case_depth - usb_a_offset_depth // distance from "back"
+    ]) {
+        color ("red") {
+                cube(
+                    [3, 14, 7],
+                    false
+                );
+        }
+    }
+    
+    // micro-usb port (power)
+    translate([
+        case_width - micro_usb_offset_width, // distance from "right"
+        -1,                                  // start far bottom of device
+        case_depth - micro_usb_offset_depth  // distance from "back"
+    ]) {
+        color ("purple") {
+            cube(
+                [9, 3, 3],
+                false
+            );    
+        }
+    }
 }