// PCB Enclosure with Lid
// Designed for 100 x 60 x 1.6 mm PCB with components up to 15 mm tall

/* [PCB Dimensions] */
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]
bottom_clearance = 4.0;      // [2:0.5:10]
pcb_xy_clearance = 1.5;      // [0.5:0.1:4.0]
lid_top_clearance = 2.0;     // [0.5:0.5:10.0]

/* [Enclosure Settings] */
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]
corner_radius = 4.0;         // [1.0:0.5:10.0]

/* [PCB Standoffs] */
pcb_hole_inset = 4.0;        // [2:0.5:10]
standoff_od = 6.5;           // [5.0:0.5:10.0]
// M3 heat-set insert hole diameter (typically ~4.0 - 4.2mm for M3 brass insert)
insert_hole_diameter = 4.2;  // [3.0:0.1:5.0]
insert_depth = 4.5;          // [3.0:0.5:8.0]

/* [Lid Fasteners] */
lid_screw_od = 8.5;          // [6.0:0.5:12.0]
lid_insert_hole_dia = 4.2;   // [3.0:0.1:5.0]
lid_insert_depth = 6.0;      // [4.0:0.5:10.0]
m3_screw_head_dia = 6.2;     // [5.0:0.1:8.0]
m3_screw_hole_dia = 3.4;     // [3.0:0.1:4.5]
countersink_angle = 90;

/* [Cutouts & Vents] */
num_vents = 6;               // [2:1:12]
vent_slot_width = 2.0;       // [1.0:0.5:5.0]
vent_slot_length = 20.0;     // [10.0:1.0:40.0]
vent_spacing = 6.0;          // [3.0:0.5:12.0]

usbc_width = 10.0;           // [8.0:0.5:14.0]
usbc_height = 4.0;           // [3.0:0.5:8.0]
usbc_above_board = 3.0;      // [0.0:0.5:10.0]

/* [Display & Colors] */
part_spacing = 20.0;         // [10:5:60]
base_color = "#2E5A88";      // Base enclosure color
lid_color = "#4682B4";       // Lid color
accent_color = "#D4AF37";    // Brass insert accents

$fn = 48;

// Derived Dimensions
inner_l = pcb_length + 2 * pcb_xy_clearance;
inner_w = pcb_width + 2 * pcb_xy_clearance;
inner_h = bottom_clearance + pcb_thickness + component_height + lid_top_clearance;

outer_l = inner_l + 2 * wall_thickness;
outer_w = inner_w + 2 * wall_thickness;
base_h = floor_thickness + inner_h;

// PCB top Z coordinate relative to bottom of base
pcb_top_z = floor_thickness + bottom_clearance + pcb_thickness;

// Helper: Rounded Rectangle 2D
module rounded_rect(w, l, r) {
    hull() {
        translate([-w/2 + r, -l/2 + r]) circle(r=r);
        translate([ w/2 - r, -l/2 + r]) circle(r=r);
        translate([-w/2 + r,  l/2 - r]) circle(r=r);
        translate([ w/2 - r,  l/2 - r]) circle(r=r);
    }
}

// Base Enclosure
module enclosure_base() {
    difference() {
        union() {
            // Main outer body
            linear_extrude(height = base_h)
                rounded_rect(outer_w, outer_l, corner_radius);
        }

        // Main inner cavity
        translate([0, 0, floor_thickness])
            linear_extrude(height = inner_h + 1)
                rounded_rect(inner_w, inner_l, max(0.5, corner_radius - wall_thickness));

        // USB-C Cutout centered on short side (front: -Y)
        // Positioned usbc_above_board mm above PCB top
        translate([0, -outer_l/2, pcb_top_z + usbc_above_board])
            rotate([-90, 0, 0])
            hull() {
                translate([-(usbc_width - usbc_height)/2, 0, -1])
                    cylinder(r = usbc_height/2, h = wall_thickness + 2);
                translate([ (usbc_width - usbc_height)/2, 0, -1])
                    cylinder(r = usbc_height/2, h = wall_thickness + 2);
            }

        // Vent slots on left (+X) and right (-X) long sides
        vent_start_y = -((num_vents - 1) * vent_spacing) / 2;
        for (side = [-1, 1]) {
            for (i = [0 : num_vents - 1]) {
                y_pos = vent_start_y + i * vent_spacing;
                // Vents centered in the upper clearance zone
                vent_z = floor_thickness + bottom_clearance + pcb_thickness + component_height / 2;
                translate([side * outer_w / 2, y_pos, vent_z])
                    rotate([0, side * 90, 0])
                    hull() {
                        translate([0, -vent_slot_length/2 + vent_slot_width/2, -wall_thickness - 1])
                            cylinder(r = vent_slot_width/2, h = 2 * wall_thickness + 2);
                        translate([0,  vent_slot_length/2 - vent_slot_width/2, -wall_thickness - 1])
                            cylinder(r = vent_slot_width/2, h = 2 * wall_thickness + 2);
                    }
            }
        }

        // Corner screw bosses holes (for M3 heat-set inserts to screw down lid)
        for (sx = [-1, 1]) {
            for (sy = [-1, 1]) {
                bx = sx * (inner_w/2 - lid_screw_od/2 + 0.5);
                by = sy * (inner_l/2 - lid_screw_od/2 + 0.5);
                translate([bx, by, base_h - lid_insert_depth])
                    cylinder(d = lid_insert_hole_dia, h = lid_insert_depth + 1);
            }
        }

        // PCB Standoff insert holes
        for (sx = [-1, 1]) {
            for (sy = [-1, 1]) {
                px = sx * (pcb_width / 2 - pcb_hole_inset);
                py = sy * (pcb_length / 2 - pcb_hole_inset);
                translate([px, py, floor_thickness + bottom_clearance - insert_depth])
                    cylinder(d = insert_hole_diameter, h = insert_depth + 1);
            }
        }
    }

    // Interior additions: Corner bosses for lid screws & PCB standoffs
    difference() {
        union() {
            // Lid screw corner bosses
            for (sx = [-1, 1]) {
                for (sy = [-1, 1]) {
                    bx = sx * (inner_w/2 - lid_screw_od/2 + 0.5);
                    by = sy * (inner_l/2 - lid_screw_od/2 + 0.5);
                    translate([bx, by, floor_thickness])
                        cylinder(d = lid_screw_od, h = inner_h);
                }
            }

            // PCB Standoff pillars
            for (sx = [-1, 1]) {
                for (sy = [-1, 1]) {
                    px = sx * (pcb_width / 2 - pcb_hole_inset);
                    py = sy * (pcb_length / 2 - pcb_hole_inset);
                    translate([px, py, floor_thickness])
                        cylinder(d = standoff_od, h = bottom_clearance);
                }
            }
        }

        // Re-cut holes in the newly added bosses
        for (sx = [-1, 1]) {
            for (sy = [-1, 1]) {
                bx = sx * (inner_w/2 - lid_screw_od/2 + 0.5);
                by = sy * (inner_l/2 - lid_screw_od/2 + 0.5);
                translate([bx, by, base_h - lid_insert_depth])
                    cylinder(d = lid_insert_hole_dia, h = lid_insert_depth + 1);
            }
        }
        for (sx = [-1, 1]) {
            for (sy = [-1, 1]) {
                px = sx * (pcb_width / 2 - pcb_hole_inset);
                py = sy * (pcb_length / 2 - pcb_hole_inset);
                translate([px, py, floor_thickness + bottom_clearance - insert_depth])
                    cylinder(d = insert_hole_diameter, h = insert_depth + 1);
            }
        }
    }
}

// Lid with countersunk screw holes and interlocking alignment lip
module enclosure_lid() {
    lip_height = 1.8;
    lip_clearance = 0.3; // gap for snug fit

    difference() {
        union() {
            // Main lid plate
            linear_extrude(height = lid_thickness)
                rounded_rect(outer_w, outer_l, corner_radius);

            // Alignment lip extending down into enclosure
            translate([0, 0, -lip_height])
                linear_extrude(height = lip_height)
                    rounded_rect(inner_w - 2 * lip_clearance, inner_l - 2 * lip_clearance, max(0.5, corner_radius - wall_thickness - lip_clearance));
        }

        // Hollow out center of alignment lip to save material and clear components
        translate([0, 0, -lip_height - 0.1])
            linear_extrude(height = lip_height + 0.2)
                rounded_rect(inner_w - 2 * wall_thickness, inner_l - 2 * wall_thickness, 2);

        // Relieve lip at corner screw bosses
        for (sx = [-1, 1]) {
            for (sy = [-1, 1]) {
                bx = sx * (inner_w/2 - lid_screw_od/2 + 0.5);
                by = sy * (inner_l/2 - lid_screw_od/2 + 0.5);
                translate([bx, by, -lip_height - 0.5])
                    cylinder(d = lid_screw_od + 1.0, h = lip_height + 1.0);
            }
        }

        // M3 Countersunk screw holes in lid
        for (sx = [-1, 1]) {
            for (sy = [-1, 1]) {
                bx = sx * (inner_w/2 - lid_screw_od/2 + 0.5);
                by = sy * (inner_l/2 - lid_screw_od/2 + 0.5);
                
                // Through hole
                translate([bx, by, -lip_height - 1])
                    cylinder(d = m3_screw_hole_dia, h = lid_thickness + lip_height + 2);
                
                // Countersink cone
                cs_depth = (m3_screw_head_dia - m3_screw_hole_dia) / (2 * tan(countersink_angle / 2));
                translate([bx, by, lid_thickness - cs_depth])
                    cylinder(r1 = m3_screw_hole_dia / 2, r2 = m3_screw_head_dia / 2, h = cs_depth + 0.01);
                translate([bx, by, lid_thickness])
                    cylinder(d = m3_screw_head_dia, h = 1.0);
            }
        }
    }
}

// Side by side assembly view
translate([-outer_w / 2 - part_spacing / 2, 0, 0]) {
    color(base_color) enclosure_base();
}

translate([outer_w / 2 + part_spacing / 2, 0, 0]) {
    color(lid_color) enclosure_lid();
}