// Arduino Uno R3 Snap-Fit Enclosure
// Parametric two-part case with standoffs, connector ports, and snap joints

/* [Board Dimensions] */
board_length = 68.6;         // [60:0.1:80]
board_width = 53.3;          // [45:0.1:65]
board_thickness = 1.6;       // [1.0:0.1:3.0]
component_height = 12.0;     // [8:0.5:20]
clearance = 1.5;             // [0.5:0.1:3.0]

/* [Enclosure Settings] */
wall_thickness = 2.0;        // [1.2:0.1:4.0]
standoff_height = 3.0;       // [2.0:0.5:8.0]
standoff_diameter = 6.0;     // [4.0:0.5:8.0]
pin_diameter = 2.8;          // [2.0:0.1:3.5]
pin_height = 2.5;            // [1.5:0.5:4.0]
corner_radius = 3.5;         // [1.0:0.5:8.0]
snap_depth = 0.5;            // [0.3:0.1:1.0]

/* [Port Dimensions] */
usb_width = 12.0;            // [10.0:0.5:15.0]
usb_height = 11.0;           // [9.0:0.5:14.0]
usb_offset_y = 31.5;         // [25.0:0.5:40.0]
barrel_width = 9.0;          // [7.0:0.5:12.0]
barrel_height = 11.0;        // [8.0:0.5:14.0]
barrel_offset_y = 3.2;       // [0.0:0.5:10.0]

/* [Display & Layout] */
print_spacing = 16.0;        // [10:1:40]
show_lid_openings = true;
base_color = "#1565C0";      // Blue
lid_color = "#1E88E5";       // Lighter Blue

/* [Calculated Dimensions] */
inner_length = board_length + 2 * clearance;
inner_width = board_width + 2 * clearance;
total_inner_height = standoff_height + board_thickness + component_height + 1.5;

outer_length = inner_length + 2 * wall_thickness;
outer_width = inner_width + 2 * wall_thickness;
base_height = standoff_height + board_thickness + 5.0; // 9.6mm
lid_height = total_inner_height - base_height + wall_thickness + 2.0; // rest of height

$fn = 40;

// Rounded box helper (centered in XY or at origin)
module rounded_box_2d(length, width, r) {
    hull() {
        translate([r, r]) circle(r=r);
        translate([length - r, r]) circle(r=r);
        translate([length - r, width - r]) circle(r=r);
        translate([r, width - r]) circle(r=r);
    }
}

module rounded_box_3d(length, width, height, r) {
    linear_extrude(height=height)
        rounded_box_2d(length, width, r);
}

// Uno mounting holes relative to board bottom-left
// (14.0, 2.5), (15.2, 50.8), (66.0, 7.6), (66.0, 35.6)
uno_hole_positions = [
    [14.0, 2.5],
    [15.2, 50.8],
    [66.0, 7.6],
    [66.0, 35.6]
];

// -------------------------------------------------------------
// BASE COMPONENT
// -------------------------------------------------------------
module enclosure_base() {
    lip_height = 2.5;
    lip_inset = wall_thickness / 2;

    difference() {
        union() {
            // Main outer shell
            rounded_box_3d(outer_length, outer_width, base_height, corner_radius);

            // Snap-fit rim / interlocking lip
            translate([wall_thickness + lip_inset/2, wall_thickness + lip_inset/2, base_height])
                linear_extrude(height=lip_height)
                difference() {
                    rounded_box_2d(inner_length + lip_inset, inner_width + lip_inset, max(1, corner_radius - lip_inset));
                    rounded_box_2d(inner_length - lip_inset, inner_width - lip_inset, max(0.5, corner_radius - lip_inset*2));
                }

            // Snap locking beads on the lip sides
            for (offset_x = [outer_length * 0.35, outer_length * 0.65]) {
                // Front and Back snap ridges
                translate([offset_x, wall_thickness + lip_inset/4, base_height + lip_height*0.6])
                    rotate([0, 90, 0])
                    cylinder(r=snap_depth, h=8, center=true);

                translate([offset_x, outer_width - (wall_thickness + lip_inset/4), base_height + lip_height*0.6])
                    rotate([0, 90, 0])
                    cylinder(r=snap_depth, h=8, center=true);
            }
        }

        // Inner cavity hollow out
        translate([wall_thickness, wall_thickness, wall_thickness])
            rounded_box_3d(inner_length, inner_width, base_height + lip_height + 2, max(0.5, corner_radius - wall_thickness));

        // Short side port cutouts (Left side, X = 0)
        // USB-B Jack cutout
        translate([-1, wall_thickness + clearance + usb_offset_y, wall_thickness + standoff_height + board_thickness])
            cube([wall_thickness + 2, usb_width, usb_height + 5]);

        // DC Barrel Jack cutout
        translate([-1, wall_thickness + clearance + barrel_offset_y, wall_thickness + standoff_height + board_thickness])
            cube([wall_thickness + 2, barrel_width, barrel_height + 5]);

        // Base ventilation slots on bottom floor
        for (i = [0:5]) {
            translate([outer_length * 0.3 + i * 6.5, outer_width * 0.3, -1])
                cube([3, outer_width * 0.4, wall_thickness + 2]);
        }
    }

    // Standoff pillars inside the base
    for (pos = uno_hole_positions) {
        px = wall_thickness + clearance + pos[0];
        py = wall_thickness + clearance + pos[1];

        translate([px, py, wall_thickness]) {
            // Support pillar
            cylinder(h=standoff_height, d=standoff_diameter);
            // Locating pin
            translate([0, 0, standoff_height])
                cylinder(h=pin_height, d=pin_diameter);
            // Pin chamfer/taper for smooth seating
            translate([0, 0, standoff_height + pin_height])
                cylinder(h=0.8, d1=pin_diameter, d2=pin_diameter * 0.6);
        }
    }

    // Corner reinforcement / resting tabs
    translate([wall_thickness, wall_thickness, wall_thickness])
        cube([2.5, 2.5, standoff_height]);
    translate([outer_length - wall_thickness - 2.5, wall_thickness, wall_thickness])
        cube([2.5, 2.5, standoff_height]);
    translate([outer_length - wall_thickness - 2.5, outer_width - wall_thickness - 2.5, wall_thickness])
        cube([2.5, 2.5, standoff_height]);
    translate([wall_thickness, outer_width - wall_thickness - 2.5, wall_thickness])
        cube([2.5, 2.5, standoff_height]);
}

// -------------------------------------------------------------
// LID COMPONENT (Printed top-side down for ideal 3D printing)
// -------------------------------------------------------------
module enclosure_lid() {
    lip_height = 2.5;
    lip_inset = wall_thickness / 2;
    lid_depth = lid_height;

    difference() {
        // Main lid shell
        rounded_box_3d(outer_length, outer_width, lid_depth, corner_radius);

        // Hollow interior
        translate([wall_thickness, wall_thickness, wall_thickness])
            rounded_box_3d(inner_length, inner_width, lid_depth + 1, max(0.5, corner_radius - wall_thickness));

        // Internal mating shelf / rebate for base rim
        translate([wall_thickness + lip_inset/2 - 0.2, wall_thickness + lip_inset/2 - 0.2, lid_depth - lip_height - 0.2])
            rounded_box_3d(inner_length + lip_inset + 0.4, inner_width + lip_inset + 0.4, lip_height + 1, max(1, corner_radius - lip_inset));

        // Snap receiver grooves inside
        for (offset_x = [outer_length * 0.35, outer_length * 0.65]) {
            translate([offset_x, wall_thickness + lip_inset/4, lid_depth - lip_height*0.4])
                rotate([0, 90, 0])
                cylinder(r=snap_depth + 0.2, h=8.5, center=true);

            translate([offset_x, outer_width - (wall_thickness + lip_inset/4), lid_depth - lip_height*0.4])
                rotate([0, 90, 0])
                cylinder(r=snap_depth + 0.2, h=8.5, center=true);
        }

        // Matching port archways on lid to complete the openings
        translate([-1, wall_thickness + clearance + usb_offset_y - 0.3, lid_depth - 3.5])
            cube([wall_thickness + 2, usb_width + 0.6, 4]);

        translate([-1, wall_thickness + clearance + barrel_offset_y - 0.3, lid_depth - 3.5])
            cube([wall_thickness + 2, barrel_width + 0.6, 4]);

        // Optional header cutouts and reset button access on top of lid
        if (show_lid_openings) {
            // Digital pin header slot
            translate([wall_thickness + clearance + 27, wall_thickness + clearance + 49.5, -1])
                cube([38, 3.2, wall_thickness + 2]);

            // Analog / Power pin header slot
            translate([wall_thickness + clearance + 34, wall_thickness + clearance + 1.2, -1])
                cube([31, 3.2, wall_thickness + 2]);

            // Reset button hole
            translate([wall_thickness + clearance + 5.5, wall_thickness + clearance + 49.5, -1])
                cylinder(d=5.0, h=wall_thickness + 2);

            // UNO embossed label / accent cooling fins
            for (i = [0:3]) {
                translate([wall_thickness + clearance + 18 + i*4, outer_width * 0.45, -0.5])
                    cube([2, outer_width * 0.25, wall_thickness]);
            }
        }
    }
}

// -------------------------------------------------------------
// ASSEMBLY / PRINT BED LAYOUT
// -------------------------------------------------------------

// Base placed on the bed
color(base_color)
    enclosure_base();

// Lid placed side-by-side on the bed (oriented flat for printing)
color(lid_color)
    translate([0, outer_width + print_spacing, 0])
        enclosure_lid();