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

/* [Clamp Specifications] */
// Maximum distance between anvil and fully retracted pad
max_opening = 50;           // [30:5:100]
// Distance from inner frame to clamping centerline
throat_depth = 40;          // [25:5:80]
// Frame beam width (out of plane)
frame_thickness = 12;       // [8:1:20]
// Frame beam height (profile depth)
beam_height = 16;           // [12:1:24]
// I-beam flange thickness
flange_thickness = 3.5;     // [2:0.5:6]
// I-beam web thickness
web_thickness = 4.0;        // [2:0.5:8]

/* [Screw & Hardware] */
screw_diameter = 8;         // [8:2:16]
screw_pitch = 2.0;          // [1.5:0.5:3.0]
screw_clearance = 0.4;      // [0.2:0.05:0.6]
screw_length = 72;          // [50:5:110]
handle_length = 50;         // [35:5:80]
handle_diameter = 9;        // [7:1:14]
ball_diameter = 5.6;        // [4:0.2:8]
ball_neck = 3.8;            // [3:0.2:6]

/* [Swivel Pad] */
pad_diameter = 16;          // [12:1:25]
pad_thickness = 7;          // [5:1:12]

/* [Display & Colors] */
// Display arrangement
layout_mode = "print";      // [print, assembled]
frame_color = "#E65100";    // Frame color (Industrial Orange)
screw_color = "#37474F";    // Screw & T-handle color (Dark Slate)
pad_color = "#FFB300";      // Swivel pad color (Amber Yellow)

$fn = 48;

// Derived dimensions
boss_outer_diameter = screw_diameter + 10;
boss_height = 14;
anvil_diameter = 16;
anvil_height = 6;

// Centerline of screw is at X = 0
// Throat depth reaches back to X = -throat_depth
// Bottom anvil top is at Y = 0
// Top boss bottom is at Y = max_opening + pad_thickness + 4

module ibeam_profile(h, w, tf, tw, r=1.5) {
    // 2D I-beam profile cross section centered at [0,0]
    // h = total height (in plane of bending), w = width (thickness)
    difference() {
        rect([h, w], rounding=r);
        // Left web pocket
        translate([0, (w - tw)/2 + tw/2])
            rect([h - 2*tf, (w - tw)/2 + 0.1], rounding=r/2);
        // Right web pocket
        translate([0, -((w - tw)/2 + tw/2)])
            rect([h - 2*tf, (w - tw)/2 + 0.1], rounding=r/2);
    }
}

module clamp_frame() {
    top_y = max_opening + pad_thickness + 4;
    spine_x = -throat_depth;
    
    difference() {
        union() {
            // Main backbone & arms using continuous curved sweep or hull segments
            // Lower arm: from spine to anvil
            hull() {
                translate([spine_x + beam_height/2, 0, frame_thickness/2])
                    cube([beam_height, beam_height, frame_thickness], center=true);
                translate([-beam_height/2, -beam_height/2, frame_thickness/2])
                    cube([beam_height, beam_height, frame_thickness], center=true);
            }
            
            // Lower corner radius
            hull() {
                translate([spine_x, -beam_height/2, 0])
                    cylinder(r=beam_height/2, h=frame_thickness);
                translate([spine_x + beam_height/2, -beam_height/2, frame_thickness/2])
                    cube([beam_height, beam_height, frame_thickness], center=true);
                translate([spine_x, 0, frame_thickness/2])
                    cube([beam_height, beam_height, frame_thickness], center=true);
            }

            // Spine (vertical column)
            hull() {
                translate([spine_x, -beam_height/4, frame_thickness/2])
                    cube([beam_height, beam_height/2, frame_thickness], center=true);
                translate([spine_x, top_y + boss_height + beam_height/4, frame_thickness/2])
                    cube([beam_height, beam_height/2, frame_thickness], center=true);
            }

            // Upper corner radius
            hull() {
                translate([spine_x, top_y + boss_height, 0])
                    cylinder(r=beam_height/2, h=frame_thickness);
                translate([spine_x + beam_height/2, top_y + boss_height, frame_thickness/2])
                    cube([beam_height, beam_height, frame_thickness], center=true);
                translate([spine_x, top_y + boss_height - beam_height/4, frame_thickness/2])
                    cube([beam_height, beam_height, frame_thickness], center=true);
            }

            // Upper arm: from spine to top boss
            hull() {
                translate([spine_x + beam_height/2, top_y + boss_height/2, frame_thickness/2])
                    cube([beam_height, beam_height, frame_thickness], center=true);
                translate([0, top_y + boss_height/2, frame_thickness/2])
                    cylinder(r=boss_outer_diameter/2, h=frame_thickness, center=true);
            }

            // Threaded Boss on upper arm
            translate([0, top_y + boss_height/2, frame_thickness/2])
                rotate([90, 0, 0])
                cylinder(r=boss_outer_diameter/2, h=boss_height, center=true);

            // Anvil Boss on lower arm
            translate([0, -anvil_height/2, frame_thickness/2])
                rotate([90, 0, 0])
                cylinder(r=anvil_diameter/2, h=anvil_height, center=true);
            
            // Support gusset under anvil
            hull() {
                translate([0, -anvil_height, frame_thickness/2])
                    rotate([90,0,0])
                    cylinder(r=anvil_diameter/2, h=1, center=true);
                translate([-beam_height, -beam_height, frame_thickness/2])
                    cube([beam_height, 2, frame_thickness], center=true);
            }
        }

        // I-beam pockets (recesses on front and back faces)
        // Recess spine
        for (side = [-1, 1]) {
            z_offset = frame_thickness/2 + side * (frame_thickness/2 - flange_thickness/2);
            pocket_depth = (frame_thickness - web_thickness)/2 + 0.1;
            
            // Spine pocket
            translate([spine_x, (top_y + boss_height)/2, (side > 0 ? frame_thickness - pocket_depth : -0.1)])
                cube([beam_height - 2*flange_thickness, top_y + boss_height - beam_height, pocket_depth + 0.1]);
            
            // Bottom arm pocket
            translate([(spine_x - beam_height/2)/2, -beam_height/2 + flange_thickness/2, (side > 0 ? frame_thickness - pocket_depth : -0.1)])
                cube([abs(spine_x) - anvil_diameter/2 - 2, beam_height - 2*flange_thickness, pocket_depth + 0.1]);
            
            // Top arm pocket
            translate([(spine_x - beam_height/2)/2, top_y + boss_height/2 - (beam_height - 2*flange_thickness)/2, (side > 0 ? frame_thickness - pocket_depth : -0.1)])
                cube([abs(spine_x) - boss_outer_diameter/2 - 2, beam_height - 2*flange_thickness, pocket_depth + 0.1]);
        }

        // M8 Internal Thread through top boss
        translate([0, top_y + boss_height + 1, frame_thickness/2])
            rotate([90, 0, 0])
            threaded_rod(
                d = screw_diameter + screw_clearance,
                l = boss_height + 3,
                pitch = screw_pitch,
                internal = true,
                orient = BACK
            );

        // Anvil flat face cleanup at Y = 0
        translate([-50, 0, -10])
            cube([100, 20, 40]);
    }
}

module lead_screw() {
    union() {
        // M8 Threaded Rod Section
        threaded_rod(
            d = screw_diameter,
            l = screw_length,
            pitch = screw_pitch,
            bevel1 = true,
            orient = UP
        );

        // Swivel Ball Joint at tip (Z = -screw_length/2)
        translate([0, 0, -screw_length/2]) {
            // Neck
            cylinder(r=ball_neck/2, h=3, center=false);
            // Ball
            translate([0, 0, -ball_diameter/2 + 0.5])
                sphere(r=ball_diameter/2);
        }

        // T-Handle Transition Hub (at Z = +screw_length/2)
        translate([0, 0, screw_length/2]) {
            // Reinforcing collar
            cylinder(r1=screw_diameter/2 + 0.5, r2=handle_diameter/2, h=4);
            
            // T-handle bar
            translate([0, 0, 4 + handle_diameter/2]) {
                rotate([0, 90, 0])
                    cylinder(r=handle_diameter/2, h=handle_length, center=true);
                // Ergonomic rounded ends
                for (s = [-1, 1]) {
                    translate([s * handle_length/2, 0, 0])
                        sphere(r=handle_diameter/2);
                }
            }
        }
    }
}

module swivel_pad() {
    socket_depth = ball_diameter * 0.75;
    difference() {
        union() {
            // Main disc with taper
            cylinder(r1=pad_diameter/2, r2=pad_diameter/2 - 1, h=pad_thickness - 2);
            translate([0, 0, pad_thickness - 2])
                cylinder(r1=pad_diameter/2 - 1, r2=ball_neck/2 + 1.8, h=2);
        }

        // Spherical socket for snap-fit
        translate([0, 0, pad_thickness - ball_diameter/2 + 0.4])
            sphere(r=ball_diameter/2 + 0.25);

        // Entry channel for ball snap
        translate([0, 0, pad_thickness - 2])
            cylinder(r=ball_neck/2 + 0.35, h=3);

        // Snap-fit flex relief slits
        for (a = [0, 90]) {
            rotate([0, 0, a])
                translate([-pad_diameter/2, -0.6, pad_thickness - socket_depth - 1])
                cube([pad_diameter, 1.2, socket_depth + 2]);
        }

        // Anti-slip waffle grip texture on face (Z = 0)
        for (gx = [-pad_diameter/2 + 2 : 2.2 : pad_diameter/2 - 2]) {
            translate([gx, -pad_diameter/2, -0.01])
                rotate([-45, 0, 0])
                cube([0.8, pad_diameter * 1.5, 0.6]);
        }
        for (gy = [-pad_diameter/2 + 2 : 2.2 : pad_diameter/2 - 2]) {
            translate([-pad_diameter/2, gy, -0.01])
                rotate([0, 45, 0])
                cube([pad_diameter * 1.5, 0.8, 0.6]);
        }
    }
}

// Layout Selection
if (layout_mode == "print") {
    // Print bed layout: Frame flat, Screw horizontal, Pad upright
    color(frame_color)
        translate([0, 0, 0])
        clamp_frame();

    color(screw_color)
        translate([28, 40, handle_diameter/2])
        rotate([0, 90, 0])
        lead_screw();

    color(pad_color)
        translate([28, -10, 0])
        swivel_pad();

} else {
    // Assembled View
    top_y = max_opening + pad_thickness + 4;
    screw_z_travel = 25; // clamping position

    color(frame_color)
        clamp_frame();

    color(screw_color)
        translate([0, top_y + boss_height/2 + screw_z_travel, frame_thickness/2])
        rotate([90, 0, 0])
        lead_screw();

    color(pad_color)
        translate([0, top_y + boss_height/2 + screw_z_travel - screw_length/2 - ball_diameter/2 - 1.5, frame_thickness/2])
        rotate([-90, 0, 0])
        swivel_pad();
}