// Two-Piece Split Ring Tube Clamp with Mounting Foot
// Designed for 25 mm OD Tube

/* [Tube & Clamp Dimensions] */
// Outer diameter of the tube to clamp
tube_od = 25.0;              // [15:0.5:50]
// Wall thickness of the clamp ring
wall_thickness = 4.0;        // [2:0.5:8]
// Axial width of the clamp along the tube
clamp_width = 12.0;          // [8:1:30]
// Clearance gap between top and bottom clamp halves
clamp_gap = 1.0;             // [0.5:0.1:3]

/* [Flange & Clamping Hardware] */
// Distance from tube outer surface to clamping bolt center
bolt_offset = 8.0;           // [5:0.5:15]
// Bolt through-hole diameter (M4 clearance)
bolt_hole_dia = 4.5;         // [3:0.1:6]
// Flange thickness
flange_thickness = 5.0;      // [3:0.5:10]
// Bolt head counterbore diameter
bolt_cb_dia = 8.0;           // [6:0.5:12]
// Bolt head counterbore depth
bolt_cb_depth = 2.5;         // [0:0.5:5]
// Include hex nut recess on bottom flange
include_nut_pocket = true;

/* [Mounting Foot Dimensions] */
// Total width of the flat mounting base foot
foot_width = 72.0;           // [45:1:100]
// Thickness of the mounting foot plate
foot_thickness = 4.0;        // [3:0.5:8]
// Width of the mounting slots (clearance for M4)
slot_width = 4.5;            // [3:0.1:6]
// Length of the mounting slots
slot_length = 9.0;           // [5:0.5:18]
// Distance from clamp center to center of each mounting slot
slot_offset = 27.5;          // [18:0.5:45]

/* [Display Settings] */
// Layout of the two halves
display_mode = "side_by_side"; // [side_by_side: Side by Side, print_flat: Flat for 3D Printing, assembled: Assembled]
// Spacing between halves in side-by-side view
part_spacing = 75.0;         // [50:5:120]

/* [Colors] */
cap_color = "DodgerBlue";
base_color = "SteelBlue";
hardware_color = "Silver";

/* [Quality] */
$fn = 72;

// Derived parameters
r_in = tube_od / 2;
r_out = r_in + wall_thickness;
bolt_x = r_in + bolt_offset;
flange_edge_x = bolt_x + bolt_hole_dia / 2 + 3.25;

// Main visual output
if (display_mode == "side_by_side") {
    // Bottom base half on the left
    translate([-part_spacing / 2, 0, 0])
        clamp_base();
    
    // Top cap half on the right (both upright for easy feature inspection)
    translate([part_spacing / 2, 0, 0])
        clamp_cap();
} else if (display_mode == "print_flat") {
    // Base sits flat on its foot
    translate([-part_spacing / 2, 0, r_out + foot_thickness])
        clamp_base();
    
    // Cap flipped flat on its mating split faces (no supports needed)
    translate([part_spacing / 2, 0, -clamp_gap / 2])
        rotate([180, 0, 0])
        clamp_cap();
} else {
    // Assembled clamp
    clamp_base();
    clamp_cap();
    
    // Semi-transparent reference tube
    %rotate([90, 0, 0])
        cylinder(r=r_in, h=clamp_width * 3, center=true);
}

// Module for the Lower Half (Base with integrated mounting foot)
module clamp_base() {
    color(base_color)
    difference() {
        union() {
            // Semicircular cradle body
            intersection() {
                rotate([90, 0, 0])
                    cylinder(r=r_out, h=clamp_width, center=true);
                translate([0, 0, -r_out])
                    cube([r_out * 2 + 2, clamp_width + 2, r_out * 2], center=true);
            }
            
            // Left and right clamping flanges
            base_flange(side=1);
            base_flange(side=-1);
            
            // Pedestal gusset transition to foot
            hull() {
                translate([0, 0, -r_out / 2])
                    cube([r_out * 1.5, clamp_width, r_out], center=true);
                translate([0, 0, -(r_out + foot_thickness / 2)])
                    cube([foot_width * 0.7, clamp_width, foot_thickness], center=true);
            }
            
            // Flat mounting foot plate
            translate([0, 0, -(r_out + foot_thickness / 2)])
                rounded_cube([foot_width, clamp_width, foot_thickness], r=3, center=true);
        }
        
        // Inner bore for 25 mm tube
        rotate([90, 0, 0])
            cylinder(r=r_in, h=clamp_width + 4, center=true);
        
        // Split plane relief gap cut
        translate([0, 0, -clamp_gap / 4])
            cube([flange_edge_x * 2 + 10, clamp_width + 4, clamp_gap / 2], center=true);
        
        // Left bolt hole (clearance Ø4.5 mm)
        translate([-bolt_x, 0, 0])
            cylinder(d=bolt_hole_dia, h=r_out * 2, center=true);
            
        // Right bolt hole (clearance Ø4.5 mm)
        translate([bolt_x, 0, 0])
            cylinder(d=bolt_hole_dia, h=r_out * 2, center=true);
            
        // Optional hex nut traps on underside of clamping flanges
        if (include_nut_pocket) {
            translate([-bolt_x, 0, -(clamp_gap / 2 + flange_thickness - 1.5)])
                rotate([0, 0, 30])
                cylinder(d=7.8, h=10, $fn=6);
                
            translate([bolt_x, 0, -(clamp_gap / 2 + flange_thickness - 1.5)])
                rotate([0, 0, 30])
                cylinder(d=7.8, h=10, $fn=6);
        }
        
        // Left mounting foot slot
        translate([-slot_offset, 0, -(r_out + foot_thickness / 2)])
            mounting_slot(slot_width, slot_length, foot_thickness + 2);
            
        // Right mounting foot slot
        translate([slot_offset, 0, -(r_out + foot_thickness / 2)])
            mounting_slot(slot_width, slot_length, foot_thickness + 2);
    }
}

// Module for the Upper Half (Cap)
module clamp_cap() {
    color(cap_color)
    difference() {
        union() {
            // Semicircular arch body
            intersection() {
                rotate([90, 0, 0])
                    cylinder(r=r_out, h=clamp_width, center=true);
                translate([0, 0, r_out])
                    cube([r_out * 2 + 2, clamp_width + 2, r_out * 2], center=true);
            }
            
            // Left and right clamping flanges
            cap_flange(side=1);
            cap_flange(side=-1);
        }
        
        // Inner bore for 25 mm tube
        rotate([90, 0, 0])
            cylinder(r=r_in, h=clamp_width + 4, center=true);
            
        // Split plane relief gap cut
        translate([0, 0, clamp_gap / 4])
            cube([flange_edge_x * 2 + 10, clamp_width + 4, clamp_gap / 2], center=true);
            
        // Left bolt through-hole
        translate([-bolt_x, 0, 0])
            cylinder(d=bolt_hole_dia, h=r_out * 3, center=true);
            
        // Right bolt through-hole
        translate([bolt_x, 0, 0])
            cylinder(d=bolt_hole_dia, h=r_out * 3, center=true);
            
        // Left counterbore for M4 socket head bolt
        translate([-bolt_x, 0, clamp_gap / 2 + flange_thickness - bolt_cb_depth])
            cylinder(d=bolt_cb_dia, h=10);
            
        // Right counterbore for M4 socket head bolt
        translate([bolt_x, 0, clamp_gap / 2 + flange_thickness - bolt_cb_depth])
            cylinder(d=bolt_cb_dia, h=10);
    }
}

// Helper module for lower flange geometry
module base_flange(side=1) {
    flange_len = flange_edge_x - r_in + 2;
    flange_cx = side * (r_in + flange_len / 2 - 1);
    
    translate([flange_cx, 0, -(clamp_gap / 2 + flange_thickness / 2)])
        rounded_cube([flange_len, clamp_width, flange_thickness], r=2.5, center=true);
        
    // Fillet reinforcement to main ring
    translate([side * (r_in + 2), 0, -(clamp_gap / 2 + flange_thickness)])
        rotate([0, side * 35, 0])
        cube([4, clamp_width, flange_thickness], center=true);
}

// Helper module for upper flange geometry
module cap_flange(side=1) {
    flange_len = flange_edge_x - r_in + 2;
    flange_cx = side * (r_in + flange_len / 2 - 1);
    
    translate([flange_cx, 0, (clamp_gap / 2 + flange_thickness / 2)])
        rounded_cube([flange_len, clamp_width, flange_thickness], r=2.5, center=true);
        
    // Fillet reinforcement to main ring
    translate([side * (r_in + 2), 0, (clamp_gap / 2 + flange_thickness)])
        rotate([0, -side * 35, 0])
        cube([4, clamp_width, flange_thickness], center=true);
}

// Helper for slotted hole elongated in X
module mounting_slot(w, len, h) {
    travel = len - w;
    hull() {
        translate([-travel / 2, 0, 0])
            cylinder(d=w, h=h, center=true);
        translate([travel / 2, 0, 0])
            cylinder(d=w, h=h, center=true);
    }
}

// Rounded box centered or keyed
module rounded_cube(size, r=2, center=true) {
    dx = size[0] - 2 * r;
    dy = size[1] - 2 * r;
    dz = size[2];
    
    shift_x = center ? 0 : size[0] / 2;
    shift_y = center ? 0 : size[1] / 2;
    shift_z = center ? 0 : size[2] / 2;
    
    translate([shift_x, shift_y, shift_z])
    hull() {
        for (x = [-dx/2, dx/2]) {
            for (y = [-dy/2, dy/2]) {
                translate([x, y, 0])
                    cylinder(r=r, h=dz, center=true);
            }
        }
    }
}