// Snap-in Cable Clip for 6 mm Cable
// Fully parametric design with lead-in funnel and adhesive base

/* [Main Parameters] */
// Cable diameter to secure (mm)
cable_diameter = 6.0;         // [3.0:0.5:16.0]

/* [Base Dimensions] */
// Base width across the cable (mm)
base_width = 20.0;            // [10.0:1.0:40.0]

// Base length along the cable (mm)
base_length = 12.0;           // [6.0:1.0:40.0]

// Base plate thickness (mm)
base_thickness = 2.0;         // [1.0:0.2:5.0]

// Corner rounding radius on base (mm)
base_corner_radius = 2.5;     // [1.0:0.5:5.0]

// Chamfer on top edge of base (mm)
base_top_chamfer = 0.5;       // [0.0:0.1:1.2]

/* [Clip Arm Parameters] */
// Snap opening throat width (mm)
opening_width = 5.5;          // [2.0:0.1:14.0]

// Wall thickness of the C-arm (mm)
wall_thickness = 1.6;         // [1.0:0.1:3.5]

// Length of the gripping clip along the cable (mm)
clip_length = 12.0;           // [6.0:1.0:30.0]

// Outward flare angle for snap lead-in (degrees)
flare_angle = 32.0;           // [15.0:1.0:45.0]

// Lead-in funnel lip height (mm)
flare_length = 1.4;           // [0.5:0.1:3.0]

// Fillet radius at base-to-arm junction (mm)
base_fillet_radius = 1.8;     // [0.5:0.1:3.5]

// Bevel/chamfer on front and back cable rims (mm)
rim_bevel = 0.6;              // [0.0:0.1:1.5]

/* [Features] */
// Deboss cable diameter text on base wing
show_size_label = true;

/* [Appearance] */
clip_color = "DeepSkyBlue";
base_color = "SteelBlue";
label_color = "AliceBlue";

/* [Quality] */
$fn = 64;

// --- Derived Calculations ---
inner_radius = cable_diameter / 2;
outer_radius = inner_radius + wall_thickness;
mid_radius = inner_radius + wall_thickness / 2;

// Center of the cable pocket in Z
center_z = base_thickness + outer_radius;

// Half opening at throat
half_throat = min(opening_width / 2, inner_radius * 0.98);

// Throat angle from vertical (+Z)
throat_angle = asin(half_throat / inner_radius);

// Centerline arc limits (angle from bottom 0 to max)
beta_max = 180 - throat_angle;

// Arc resolution
num_arc_pts = 36;

// Centerline arc points
arc_points = [
    for (i = [0 : num_arc_pts])
        let(b = -beta_max + (2 * beta_max * i / num_arc_pts))
        [mid_radius * sin(b), center_z - mid_radius * cos(b)]
];

// Flare tips extending outward
right_neck_pt = arc_points[num_arc_pts];
right_tip_pt = [
    right_neck_pt[0] + flare_length * sin(flare_angle),
    right_neck_pt[1] + flare_length * cos(flare_angle)
];

left_neck_pt = arc_points[0];
left_tip_pt = [
    -right_tip_pt[0],
    right_tip_pt[1]
];

// Complete path of the C-arm centerline
centerline_pts = concat([left_tip_pt], arc_points, [right_tip_pt]);

// --- Main Model Assembly ---
union() {
    // Base plate
    color(base_color)
    base_plate();

    // C-shaped gripping arm with fillets and chamfered rims
    color(clip_color)
    clip_arm_assembly();
}

// --- Modules ---

// Flat adhesive base with rounded corners and top chamfer
module base_plate() {
    difference() {
        hull() {
            for (sx = [-1, 1]) {
                for (sy = [-1, 1]) {
                    translate([
                        sx * (base_width / 2 - base_corner_radius),
                        sy * (base_length / 2 - base_corner_radius),
                        0
                    ]) {
                        cylinder(
                            r1 = base_corner_radius,
                            r2 = max(0.5, base_corner_radius - base_top_chamfer),
                            h = base_thickness
                        );
                    }
                }
            }
        }

        // Optional size marking debossed on right wing
        if (show_size_label && (base_width / 2 - outer_radius) > 2.5) {
            translate([
                (base_width / 2 + outer_radius) / 2,
                0,
                base_thickness - 0.3
            ]) {
                linear_extrude(height = 0.5) {
                    rotate([0, 0, 90])
                    text(
                        str(cable_diameter, "mm"),
                        size = min(2.5, base_length * 0.3),
                        halign = "center",
                        valign = "center",
                        font = "Liberation Sans:style=Bold"
                    );
                }
            }
        }
    }
}

// 2D cross section of the C-arm
module arm_cross_section_2d() {
    for (i = [0 : len(centerline_pts) - 2]) {
        hull() {
            translate(centerline_pts[i])
                circle(d = wall_thickness, $fn = 32);
            translate(centerline_pts[i + 1])
                circle(d = wall_thickness, $fn = 32);
        }
    }
}

// 2D fillet wedge between outer circle and base
module fillet_wedge_2d(side = 1) {
    // Tangent fillet radius
    rf = base_fillet_radius;
    zf = base_thickness + rf;
    delta_z = zf - center_z;
    rad_sum = outer_radius + rf;

    if (rad_sum > abs(delta_z)) {
        xf = sqrt(pow(rad_sum, 2) - pow(delta_z, 2));

        // Wedge area between clip and base
        translate([side * xf, zf])
        difference() {
            // Triangular / rectangular filling envelope
            translate([side > 0 ? -xf : 0, -rf])
                square([xf, rf + 0.01]);

            // Concave fillet cutout
            circle(r = rf, $fn = 32);
        }
    }
}

// Complete C-shaped arm assembly extruded along Y with rim bevels
module clip_arm_assembly() {
    difference() {
        // Main extruded arm with transition fillets
        translate([0, -clip_length / 2, 0])
        rotate([-90, 0, 0])
        linear_extrude(height = clip_length) {
            arm_cross_section_2d();
            fillet_wedge_2d(side = 1);
            fillet_wedge_2d(side = -1);
        }

        // Clean out the inner cylindrical cable bore
        translate([0, -clip_length, center_z])
        rotate([-90, 0, 0])
        cylinder(r = inner_radius, h = clip_length * 2, $fn = 64);

        // Front and back rim lead-in bevels to prevent cable chafing
        if (rim_bevel > 0) {
            // Front rim bevel
            translate([0, -clip_length / 2, center_z])
            rotate([-90, 0, 0])
            cylinder(
                r1 = inner_radius + rim_bevel,
                r2 = inner_radius,
                h = rim_bevel + 0.05,
                $fn = 48
            );

            // Back rim bevel
            translate([0, clip_length / 2 - rim_bevel, center_z])
            rotate([-90, 0, 0])
            cylinder(
                r1 = inner_radius,
                r2 = inner_radius + rim_bevel,
                h = rim_bevel + 0.05,
                $fn = 48
            );
        }
    }
}