// Parametric PCB Enclosure with Lid
// Designed for 100 x 60 x 1.6 mm PCB with 15 mm component height

/* [PCB Specifications] */
pcb_length = 100.0;          // [50:1:200]
pcb_width = 60.0;            // [30:1:150]
pcb_thickness = 1.6;         // [0.8:0.1:3.2]
component_height = 15.0;     // [5:1:40]
pcb_standoff_inset = 4.0;    // [2:0.5:10]

/* [Enclosure Dimensions] */
wall_thickness = 2.4;        // [1.5:0.1:5.0]
floor_thickness = 2.4;       // [1.5:0.1:5.0]
lid_thickness = 2.4;         // [1.5:0.1:5.0]
pcb_clearance = 1.5;         // [0.5:0.1:4.0]
standoff_height = 5.0;       // [3:0.5:12]
lid_lip_height = 2.0;        // [1:0.5:5]
corner_radius = 4.0;         // [1:0.5:10]

/* [Mounting & Fasteners] */
pcb_insert_dia = 4.2;        // [3.0:0.1:6.0] // M3 heat-set insert hole
pcb_boss_dia = 7.0;          // [5.0:0.5:12.0]
lid_screw_dia = 3.3;         // [2.5:0.1:4.5]  // M3 clearance
lid_screw_head_dia = 6.2;    // [4.5:0.1:8.0]  // M3 countersink head
lid_insert_dia = 4.2;        // [3.0:0.1:6.0]  // M3 heat-set for lid posts
lid_post_dia = 8.0;          // [6.0:0.5:12.0]

/* [Features] */
usb_width = 10.0;            // [8:0.5:16]
usb_height = 4.0;            // [3:0.5:8]
usb_height_above_pcb = 3.0;  // [1:0.5:10]
vent_count = 6;              // [0:1:12]
vent_length = 20.0;          // [10:1:40]
vent_height = 2.0;           // [1:0.5:5]

/* [Display & Colors] */
part_spacing = 25.0;         // [10:5:80]
base_color = "SteelBlue";
lid_color = "SlateGray";
pcb_color = "ForestGreen";
show_pcb_ghost = true;

$fn = 48;

// Derived dimensions
inner_l = pcb_length + 2 * pcb_clearance;
inner_w = pcb_width + 2 * pcb_clearance;
inner_h = standoff_height + pcb_thickness + component_height + 1.5; // 1.5mm top margin
outer_l = inner_l + 2 * wall_thickness;
outer_w = inner_w + 2 * wall_thickness;
outer_h = inner_h + floor_thickness;

// PCB Standoff positions (relative to center)
pcb_hole_x = (pcb_length / 2) - pcb_standoff_inset;
pcb_hole_y = (pcb_width / 2) - pcb_standoff_inset;

// Lid corner screw positions (near outer corners inside the box)
lid_screw_x = (inner_l / 2) - (lid_post_dia / 2) + 0.5;
lid_screw_y = (inner_w / 2) - (lid_post_dia / 2) + 0.5;

// Rounded rectangle 2D helper
module rounded_rect_2d(size, r) {
    w = size[0];
    h = size[1];
    offset(r=r) square([w - 2*r, h - 2*r], center=true);
}

// 3D Rounded box with flat top/bottom
module rounded_box(size, r) {
    linear_extrude(height=size[2])
        rounded_rect_2d([size[0], size[1]], r);
}

// USB-C pill/rounded-rect shape
module usb_c_profile(w, h, depth) {
    r = min(h/2, 1.5);
    rotate([90, 0, 90])
    linear_extrude(height=depth, center=true)
        rounded_rect_2d([w, h], r);
}

// Vent slot pill shape
module vent_slot(length, height, depth) {
    rotate([90, 0, 0])
    linear_extrude(height=depth, center=true)
        rounded_rect_2d([length, height], height/2);
}

// ==========================================
// BASE ENCLOSURE
// ==========================================
module enclosure_base() {
    difference() {
        union() {
            // Main outer shell
            rounded_box([outer_l, outer_w, outer_h], corner_radius);

            // Internal lid corner screw bosses
            for (sx = [-1, 1]) {
                for (sy = [-1, 1]) {
                    translate([sx * lid_screw_x, sy * lid_screw_y, floor_thickness])
                        cylinder(h=inner_h, d=lid_post_dia);
                }
            }

            // PCB Mounting Standoffs
            for (sx = [-1, 1]) {
                for (sy = [-1, 1]) {
                    translate([sx * pcb_hole_x, sy * pcb_hole_y, floor_thickness])
                        cylinder(h=standoff_height, d=pcb_boss_dia);
                }
            }
        }

        // Inner cavity cutout
        translate([0, 0, floor_thickness])
            rounded_box([inner_l, inner_w, inner_h + 1], max(0.5, corner_radius - wall_thickness));

        // Lid alignment recess (lip step) around top rim
        translate([0, 0, outer_h - lid_lip_height])
            difference() {
                translate([0, 0, -0.01])
                    rounded_box([outer_l + 1, outer_w + 1, lid_lip_height + 0.1], corner_radius);
                rounded_box([outer_l - 2*(wall_thickness/2), outer_w - 2*(wall_thickness/2), lid_lip_height + 1], max(0.5, corner_radius - wall_thickness/2));
            }

        // Lid screw boss heat-set insert holes
        for (sx = [-1, 1]) {
            for (sy = [-1, 1]) {
                translate([sx * lid_screw_x, sy * lid_screw_y, outer_h - 7])
                    cylinder(h=7.1, d=lid_insert_dia);
            }
        }

        // PCB standoff heat-set insert holes
        for (sx = [-1, 1]) {
            for (sy = [-1, 1]) {
                translate([sx * pcb_hole_x, sy * pcb_hole_y, floor_thickness + standoff_height - 4.5])
                    cylinder(h=4.6, d=pcb_insert_dia);
            }
        }

        // USB-C Cutout centered on -X short side, 3mm above PCB
        pcb_top_z = floor_thickness + standoff_height + pcb_thickness;
        usb_center_z = pcb_top_z + usb_height_above_pcb;
        translate([-outer_l/2, 0, usb_center_z])
            usb_c_profile(usb_width, usb_height, wall_thickness * 3);

        // Vent slots on both long sides (+Y and -Y walls)
        if (vent_count > 0) {
            vent_total_span = inner_l - 2 * lid_post_dia - 10;
            vent_spacing_z = min(3.5, (inner_h - 10) / (vent_count > 1 ? (vent_count - 1) : 1));
            
            // Distribute 6 slots (3 rows x 2 columns or 6 vertical stacks)
            // Let's create a clean 2-row x 3-column array or 3-row x 2-column on each side
            for (col = [-1, 0, 1]) {
                for (row = [0, 1]) {
                    x_pos = col * (vent_length * 0.95);
                    z_pos = floor_thickness + standoff_height + 4 + row * (vent_height + 3.0);
                    
                    // +Y side
                    translate([x_pos, outer_w/2, z_pos])
                        vent_slot(vent_length, vent_height, wall_thickness * 3);
                    // -Y side
                    translate([x_pos, -outer_w/2, z_pos])
                        vent_slot(vent_length, vent_height, wall_thickness * 3);
                }
            }
        }
    }
}

// ==========================================
// LID WITH COUNTERSUNK SCREWS & INTERLOCK LIP
// ==========================================
module enclosure_lid() {
    difference() {
        union() {
            // Main lid plate
            rounded_box([outer_l, outer_w, lid_thickness], corner_radius);

            // Alignment lip / rim extending downwards into base
            translate([0, 0, -lid_lip_height])
                rounded_box([outer_l - 2*(wall_thickness/2) - 0.4, outer_w - 2*(wall_thickness/2) - 0.4, lid_lip_height], max(0.5, corner_radius - wall_thickness/2));
        }

        // Inner hollow inside alignment lip to save material & weight
        translate([0, 0, -lid_lip_height - 0.1])
            rounded_box([inner_l, inner_w, lid_lip_height + 0.1], max(0.5, corner_radius - wall_thickness));

        // 4 M3 Countersunk Screw Holes
        for (sx = [-1, 1]) {
            for (sy = [-1, 1]) {
                translate([sx * lid_screw_x, sy * lid_screw_y, -lid_lip_height - 1]) {
                    // Through hole
                    cylinder(h=lid_thickness + lid_lip_height + 2, d=lid_screw_dia);
                    // Countersunk head cone
                    translate([0, 0, lid_lip_height + 1 + lid_thickness - (lid_screw_head_dia - lid_screw_dia)/2])
                        cylinder(h=(lid_screw_head_dia - lid_screw_dia)/2 + 0.1, d1=lid_screw_dia, d2=lid_screw_head_dia);
                }
            }
        }

        // Decorative subtle top surface chamfer/recess or text label
        translate([0, 0, lid_thickness - 0.4])
            rounded_box([outer_l - 12, outer_w - 12, 0.5], corner_radius);
    }
}

// ==========================================
// PCB GHOST PREVIEW
// ==========================================
module pcb_preview() {
    translate([0, 0, floor_thickness + standoff_height]) {
        // PCB board
        difference() {
            color(pcb_color, 0.85)
                rounded_box([pcb_length, pcb_width, pcb_thickness], 1.5);
            // 4 Corner holes
            for (sx = [-1, 1]) {
                for (sy = [-1, 1]) {
                    translate([sx * pcb_hole_x, sy * pcb_hole_y, -0.5])
                        cylinder(h=pcb_thickness + 1, d=3.2);
                }
            }
        }

        // Representative components
        color("DimGray", 0.7) {
            // Main MCU / SoC
            translate([0, 0, pcb_thickness])
                cube([18, 18, 2.5], center=true);
            // Tall electrolytic capacitors / modules up to component_height
            translate([25, 12, pcb_thickness + component_height/2])
                cylinder(h=component_height, d=10, center=true);
            translate([25, -12, pcb_thickness + component_height/2])
                cylinder(h=component_height, d=10, center=true);
            // USB connector on board
            translate([-pcb_length/2 + 4, 0, pcb_thickness + usb_height/2])
                cube([8, usb_width - 1, usb_height], center=true);
        }
    }
}

// ==========================================
// SCENE ASSEMBLY (BASE & LID SIDE BY SIDE)
// ==========================================
// Base Enclosure on left
translate([-(outer_l + part_spacing) / 2, 0, 0]) {
    color(base_color)
        enclosure_base();
    
    if (show_pcb_ghost) {
        pcb_preview();
    }
}

// Lid on right (presented top up with countersunk screw holes visible)
translate([(outer_l + part_spacing) / 2, 0, lid_lip_height]) {
    color(lid_color)
        enclosure_lid();
}