include <BOSL2/std.scad>
include <BOSL2/threading.scad>

/* [Clamp Dimensions] */
opening_capacity = 50;   // [30:5:100] Maximum jaw opening (mm)
throat_depth = 40;       // [25:5:80] Throat depth from screw centerline (mm)
frame_thickness = 14;    // [10:1:22] Frame out-of-plane thickness / width (mm)
frame_beam_height = 14;  // [10:1:25] Frame beam profile depth (mm)
flange_depth = 2.5;      // [1.5:0.5:5] I-beam recess depth (mm)
flange_wall = 2.5;       // [1.5:0.5:5] I-beam perimeter wall thickness (mm)

/* [Screw & Drive] */
screw_diameter = 8;      // [8:1:14] Screw outer diameter (mm)
screw_pitch = 2.0;       // [1.5:0.5:3.0] Thread pitch (mm)
thread_clearance = 0.3;  // [0.1:0.05:0.6] Clearance on internal threads (mm)
screw_total_length = 72; // [50:2:120] Total length of threaded section (mm)
handle_type = "T-bar";   // [T-bar, Knob] Handle style
handle_width = 46;       // [30:2:70] Width of T-handle (mm)

/* [Swivel Pad] */
pad_diameter = 16;       // [12:1:25] Diameter of clamping pad (mm)
pad_thickness = 6;       // [4:1:10] Thickness of clamping pad (mm)
ball_joint_diameter = 5.5; // [4.0:0.5:8.0] Swivel ball joint diameter (mm)

/* [Display & Colors] */
view_mode = "print";     // [print: Print Layout (Flat), assembled: Assembled View]
frame_color = "SteelBlue";
screw_color = "Gold";
handle_color = "DarkSlateGray";
pad_color = "OrangeRed";

$fn = 48;

// Derived geometry constants
boss_od = max(18, screw_diameter + 10);
boss_len = 16;
anvil_diameter = 16;
anvil_height = 8;
frame_inner_x = throat_depth;
frame_inner_y = opening_capacity + 12; // Extra travel room for screw retraction
frame_outer_x = frame_inner_x + frame_beam_height;
frame_outer_y = frame_inner_y + 2 * frame_beam_height;

// ==========================================
// Master Assembly / Layout
// ==========================================

if (view_mode == "assembled") {
    // Frame
    color(frame_color)
        c_frame();

    // Screw & Handle positioned in clamping mode
    clamping_pos = opening_capacity * 0.45; // Screw extended partly
    translate([0, frame_inner_y / 2 + boss_len / 2 - clamping_pos, 0]) {
        color(screw_color)
            screw_shaft();

        translate([0, screw_total_length / 2 + 7, 0])
            color(handle_color)
                t_handle();

        translate([0, -screw_total_length / 2 - 3.5, 0])
            rotate([0, 10, 0]) // slight tilt to illustrate swivel
                color(pad_color)
                    swivel_pad();
    }
} else {
    // Print Layout: flat and ready for slicing
    // 1. Frame lying flat on XY
    color(frame_color)
        translate([0, 0, frame_thickness / 2])
            c_frame();

    // 2. Screw standing or lying flat
    color(screw_color)
        translate([frame_outer_x + 18, 0, screw_diameter / 2 + 0.5])
            rotate([90, 0, 0])
                screw_shaft();

    // 3. T-Handle flat on bed
    color(handle_color)
        translate([frame_outer_x + 36, -15, 6])
            rotate([0, 0, 90])
                t_handle();

    // 4. Swivel Pad flat with flat face on bed
    color(pad_color)
        translate([frame_outer_x + 36, 25, pad_thickness / 2])
            rotate([180, 0, 0])
                swivel_pad();
}

// ==========================================
// Frame Module
// ==========================================
module c_frame() {
    difference() {
        union() {
            // Main C-body extrusion with rounded outside corners
            linear_extrude(height = frame_thickness, center = true, convexity = 10) {
                difference() {
                    // Outer rounded hull
                    offset(r = 4) offset(delta = -4) {
                        polygon(points = [
                            [-boss_od / 2 + 2, frame_inner_y / 2 + boss_len],
                            [frame_outer_x, frame_inner_y / 2 + boss_len],
                            [frame_outer_x, -frame_inner_y / 2 - anvil_height],
                            [-anvil_diameter / 2, -frame_inner_y / 2 - anvil_height],
                            [-anvil_diameter / 2, -frame_inner_y / 2],
                            [frame_inner_x, -frame_inner_y / 2 + 6],
                            [frame_inner_x, frame_inner_y / 2 - 6],
                            [-boss_od / 2 + 2, frame_inner_y / 2]
                        ]);
                    }

                    // Throat opening cutout
                    polygon(points = [
                        [-boss_od, frame_inner_y / 2],
                        [frame_inner_x, frame_inner_y / 2],
                        [frame_inner_x, -frame_inner_y / 2],
                        [-anvil_diameter, -frame_inner_y / 2]
                    ]);
                }
            }

            // Upper threaded boss reinforcement
            translate([0, frame_inner_y / 2 + boss_len / 2, 0])
                rotate([90, 0, 0])
                    cylinder(h = boss_len, d = boss_od, center = true);

            // Lower anvil pad (fixed jaw)
            translate([0, -frame_inner_y / 2 - anvil_height / 2, 0])
                rotate([90, 0, 0])
                    cylinder(h = anvil_height, d = anvil_diameter, center = true);
        }

        // Internal M8 Lead Screw Thread in upper boss
        translate([0, frame_inner_y / 2 + boss_len + 1, 0])
            rotate([90, 0, 0])
                threaded_rod(
                    d = screw_diameter + thread_clearance * 2,
                    l = boss_len + 4,
                    pitch = screw_pitch,
                    internal = true,
                    orient = BACK
                );

        // I-Beam recess on TOP face (+Z)
        translate([0, 0, frame_thickness / 2 - flange_depth / 2 + 0.01])
            i_beam_cutout();

        // I-Beam recess on BOTTOM face (-Z)
        translate([0, 0, -frame_thickness / 2 + flange_depth / 2 - 0.01])
            i_beam_cutout();

        // Chamfer on anvil clamping surface
        translate([0, -frame_inner_y / 2, 0])
            rotate([90, 0, 0])
                cylinder(h = 0.8, d1 = anvil_diameter + 1, d2 = anvil_diameter - 1, center = true);
    }
}

// Recess cutout for I-beam cross-section
module i_beam_cutout() {
    linear_extrude(height = flange_depth + 0.02, center = true) {
        offset(r = -flange_wall) {
            polygon(points = [
                [boss_od / 2 - 1, frame_inner_y / 2 + boss_len - 2],
                [frame_outer_x - 1, frame_inner_y / 2 + boss_len - 2],
                [frame_outer_x - 1, -frame_inner_y / 2 - anvil_height + 2],
                [anvil_diameter / 2 - 1, -frame_inner_y / 2 - anvil_height + 2],
                [anvil_diameter / 2 - 1, -frame_inner_y / 2 + 2],
                [frame_inner_x, -frame_inner_y / 2 + 8],
                [frame_inner_x, frame_inner_y / 2 - 8],
                [boss_od / 2 - 1, frame_inner_y / 2 + 2]
            ]);
        }
    }
}

// ==========================================
// Screw Shaft Module
// ==========================================
module screw_shaft() {
    union() {
        // Main Threaded Section
        threaded_rod(
            d = screw_diameter,
            l = screw_total_length,
            pitch = screw_pitch,
            orient = BACK
        );

        // Top collar connecting to handle
        translate([0, screw_total_length / 2 + 3, 0])
            rotate([90, 0, 0])
                cylinder(h = 6, d = screw_diameter + 2, center = true);

        // Hex or squared keyed stud for handle press-fit/lock
        translate([0, screw_total_length / 2 + 7, 0])
            rotate([90, 0, 0])
                cylinder(h = 4, d = screw_diameter, $fn = 6, center = true);

        // Ball joint neck & ball at screw tip
        translate([0, -screw_total_length / 2, 0]) {
            // Neck
            rotate([90, 0, 0])
                cylinder(h = 3, d = ball_joint_diameter * 0.55, center = false);

            // Ball joint
            translate([0, -3 - ball_joint_diameter / 2, 0])
                sphere(d = ball_joint_diameter);
        }
    }
}

// ==========================================
// T-Handle Module
// ==========================================
module t_handle() {
    difference() {
        union() {
            // Central hub
            cylinder(h = 12, d = screw_diameter + 5, center = true);

            // Crossbar wings
            hull() {
                translate([-handle_width / 2 + 4, 0, 0])
                    sphere(d = 8);
                translate([handle_width / 2 - 4, 0, 0])
                    sphere(d = 8);
                cylinder(h = 9, d = screw_diameter + 4, center = true);
            }

            // Textured grip ridges on ends
            for (side = [-1, 1]) {
                translate([side * (handle_width / 2 - 4), 0, 0])
                    sphere(d = 9);
            }
        }

        // Hex socket to lock onto screw shaft
        cylinder(h = 13, d = screw_diameter + 0.3, $fn = 6, center = true);

        // Ergonomic thumb scallops
        translate([0, 0, 6])
            rotate([0, 90, 0])
                cylinder(h = handle_width + 2, d = 4, center = true);
    }
}

// ==========================================
// Swivel Pad Module
// ==========================================
module swivel_pad() {
    difference() {
        union() {
            // Main circular pad body with rounded outer edge
            cylinder(h = pad_thickness, d = pad_diameter, center = true);

            // Gripping knurled face ridges on the front clamping face
            for (i = [-3:1:3]) {
                translate([i * 2, 0, pad_thickness / 2])
                    cube([0.8, pad_diameter * 0.85, 0.6], center = true);
            }
        }

        // Chamfer outer rim
        translate([0, 0, pad_thickness / 2])
            rotate_extrude()
                translate([pad_diameter / 2, 0, 0])
                    circle(r = 0.8);

        // Spherical socket for ball joint with snap-fit opening
        translate([0, 0, -pad_thickness / 2 + 2.8]) {
            // Ball cavity with clearance
            sphere(d = ball_joint_diameter + 0.35);

            // Entry funnel / snap neck
            translate([0, 0, -3])
                cylinder(h = 4, d1 = ball_joint_diameter * 0.75, d2 = ball_joint_diameter * 0.65, center = true);

            // Expansion relief slits for easy snap-on action
            for (a = [0, 90]) {
                rotate([0, 0, a])
                    cube([ball_joint_diameter * 1.6, 0.9, 6], center = true);
            }
        }
    }
}