// Raspberry Pi Pico Two-Piece Friction-Fit Enclosure
// Compatible with standard Raspberry Pi Pico / Pico W / Pico 2

/* [Display Settings] */
// View assembled enclosure or side-by-side print layout
assembled_view = false;
// Explode distance when assembled
explode_distance = 0; // [0:1:40]

/* [Board Specifications] */
board_length = 51.0;
board_width = 21.0;
board_thickness = 1.0;
hole_dia = 2.1;
hole_inset_long = 4.8; // Inset from long edge (Y axis)
hole_inset_short = 2.0; // Inset from short edge (X axis)

/* [Enclosure Dimensions] */
wall_thickness = 2.0;  // [1.5:0.1:3.5]
board_clearance = 1.0; // [0.5:0.1:2.5]
floor_thickness = 2.0; // [1.5:0.1:3.5]
lid_thickness = 2.0;   // [1.5:0.1:3.5]
cavity_depth = 9.0;    // [6.0:0.5:15.0]
outer_corner_radius = 3.0; // [1.0:0.5:5.0]

/* [Mounting Posts] */
standoff_height = 3.0; // [2.0:0.5:6.0]
standoff_outer_dia = 3.8;
pin_dia = 1.9;         // Sized for snug fit into Ø2.1 mm holes
pin_height = 1.8;      // Height above standoff shoulder

/* [Lid & Friction Fit] */
lip_thickness = 1.0;   // [0.8:0.1:1.5]
lip_depth = 2.5;       // [1.5:0.5:5.0]
lip_clearance = 0.15;  // [0.05:0.05:0.4]

/* [Cutout Dimensions] */
usb_width = 8.0;       // [7.0:0.5:12.0]
usb_height = 3.5;      // [3.0:0.5:6.0]

/* [Appearance] */
base_color = "#2c3e50";
lid_color = "#2980b9";
board_color = "#27ae60";
show_pico_board = true;

$fn = 48;

// Computed cavity and exterior dimensions
inner_len = board_length + 2 * board_clearance; // 53 mm
inner_wid = board_width + 2 * board_clearance;   // 23 mm
outer_len = inner_len + 2 * wall_thickness;      // 57 mm
outer_wid = inner_wid + 2 * wall_thickness;      // 27 mm
base_total_height = floor_thickness + cavity_depth; // 11 mm
inner_radius = max(0.5, outer_corner_radius - wall_thickness);

// Hole coordinate offsets from board center
hole_x = board_length / 2 - hole_inset_short; // 23.5 mm
hole_y = board_width / 2 - hole_inset_long;   // 5.7 mm

// 2D rounded rectangle helper
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);
    }
}

// 3D rounded prism
module rounded_box(len, wid, h, r) {
    linear_extrude(height=h)
        rounded_rect(len, wid, r);
}

// Raspberry Pi Pico Base Enclosure
module pico_base() {
    difference() {
        // Outer body
        rounded_box(outer_len, outer_wid, base_total_height, outer_corner_radius);

        // Internal cavity
        translate([0, 0, floor_thickness])
            rounded_box(inner_len, inner_wid, cavity_depth + 1, inner_radius);

        // Micro-USB cutout (centered on short end at board level)
        // Board sits on 3 mm posts: PCB top is at floor_thickness + standoff_height
        translate([
            -outer_len / 2 - 1,
            -usb_width / 2,
            floor_thickness + standoff_height
        ])
            cube([wall_thickness + 2, usb_width, usb_height]);

        // Small pry notch at the seam for easy lid removal
        translate([outer_len / 2 - 0.8, -3, base_total_height - 1.2])
            cube([2, 6, 2]);
    }

    // Four standoff posts with guide pins
    for (sx = [-hole_x, hole_x]) {
        for (sy = [-hole_y, hole_y]) {
            translate([sx, sy, floor_thickness]) {
                // Standoff boss (board rests on this shoulder)
                cylinder(h=standoff_height, d=standoff_outer_dia);
                // Retaining pin (passes through board mounting hole)
                translate([0, 0, standoff_height])
                    cylinder(h=pin_height, d1=pin_dia, d2=pin_dia * 0.9);
            }
        }
    }
}

// Friction-fit Lid
module pico_lid() {
    lip_len = inner_len - 2 * lip_clearance;
    lip_wid = inner_wid - 2 * lip_clearance;
    lip_r = max(0.5, inner_radius - lip_clearance);

    union() {
        // Main top plate
        rounded_box(outer_len, outer_wid, lid_thickness, outer_corner_radius);

        // Friction-fit perimeter lip
        translate([0, 0, lid_thickness]) {
            difference() {
                // Outer perimeter of lip
                rounded_box(lip_len, lip_wid, lip_depth, lip_r);

                // Hollow interior of lip
                translate([0, 0, -0.1])
                    rounded_box(
                        lip_len - 2 * lip_thickness,
                        lip_wid - 2 * lip_thickness,
                        lip_depth + 0.2,
                        max(0.3, lip_r - lip_thickness)
                    );

                // USB port clearance relief in lip
                translate([-lip_len / 2 - 1, -usb_width / 2 - 0.5, -0.1])
                    cube([lip_thickness + 2, usb_width + 1, lip_depth + 0.2]);
            }
        }

        // Tactile embossed indicator on the top surface
        translate([0, 0, -0.4]) {
            // Elegant debossed logo groove
            difference() {
                // Decorative indicator
            }
        }
    }
}

// Decorative model of the Pico board for visualization
module pico_pcb() {
    color(board_color) {
        difference() {
            // Board substrate
            rounded_box(board_length, board_width, board_thickness, 1.0);

            // 4 mounting holes
            for (sx = [-hole_x, hole_x]) {
                for (sy = [-hole_y, hole_y]) {
                    translate([sx, sy, -0.5])
                        cylinder(h=board_thickness + 1, d=hole_dia);
                }
            }
        }
    }

    // Micro-USB connector mockup
    color("#bdc3c7")
        translate([-board_length / 2 - 1.2, -3.75, board_thickness])
            cube([5.5, 7.5, 2.8]);

    // RP2040 chip mockup
    color("#1e272c")
        translate([-2, -3.5, board_thickness])
            cube([7, 7, 1.0]);

    // BOOTSEL button mockup
    color("#ecf0f1")
        translate([6, 3, board_thickness])
            cylinder(h=1.5, d=3);
}

// Scene layout
spacing = outer_wid + 10;

if (assembled_view) {
    // Assembled View
    color(base_color)
        pico_base();

    if (show_pico_board) {
        translate([0, 0, floor_thickness + standoff_height])
            pico_pcb();
    }

    translate([0, 0, base_total_height + explode_distance])
        rotate([180, 0, 0])
        translate([0, 0, -lid_thickness])
            color(lid_color)
                pico_lid();
} else {
    // Side-by-side print layout (both flat on print bed)
    translate([0, -spacing / 2, 0]) {
        color(base_color)
            pico_base();

        if (show_pico_board) {
            translate([0, 0, floor_thickness + standoff_height])
                pico_pcb();
        }
    }

    // Lid placed top-down on bed for supportless 3D printing
    translate([0, spacing / 2, 0]) {
        color(lid_color)
            pico_lid();
    }
}