363 lines
15 KiB
OpenSCAD
363 lines
15 KiB
OpenSCAD
// Parametric Expansion Card
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// An OpenSCAD implementation of a basic enclosure of an Expansion Card for
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// use with Framework products like the Framework Laptop.
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//
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// See https://frame.work for more information about Framework products and
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// additional documentation around Expansion Cards.
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// Parametric Expansion Card © 2021 by Nirav Patel at Framework Computer LLC
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// is licensed under Attribution 4.0 International.
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// To view a copy of this license, visit http://creativecommons.org/licenses/by/4.0/
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// The basic dimensions of an Expansion Card
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base = [30.0, 32.0, 6.8];
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// The extension for the SMA connectors & EG95
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base_ext = [40, 20.2, 16.5];
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// The dimensions of the NSCCP sim holder
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sim = [13.5, 13, 1.37];
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bay = [12, 8.95, 0.92];
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// The default wall thickness
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side_wall = 1.5;
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// Size and location of the typical PCB
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pcb_gap = 0.5;
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pcb = [26.0, 30.0, 0.8];
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pcb_h = 3.05;
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// USB-C plug dimensions
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usb_c_r = 1.315;
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usb_c_w = 5.86+usb_c_r*2;
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usb_c_h = 2.2;
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rail_h = 4.25; // to top of rail
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// Boss locations matching the other Framework Expansion Cards
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boss_inc_x = 4.2;
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boss_r = 1.5;
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boss_inc_y = 18.5+boss_r;
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boss_ext_y = 8.57;
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boss_ext_x = 4;
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boss_ext_r = 2.5;
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boss_ext_inner = 2.1;
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boss_ext_top_y = 6;
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lid_boss_r = 1.05;
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lid_wall_thickness = 3+side_wall;
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gap = 0.25;
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sma_height = 11.28;
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sma = 10.035;
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hollow_bottom_z = 0.7;
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bottom_thickness = hollow_bottom_z+0.2;
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ext_screw_hole = 2.5+side_wall;
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ledge_cut = 0.6;
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ledge_cut_d = 3.2;
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led_guide = [1.2, 10.65];
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led_guide_stopper = [1.5, 1,];
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// The rail cutout in the sides of the card
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module rail(make_printable) {
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rail_depth = 0.81;
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rail_flat_h = 0.32;
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mirror([0, 1, 0]) {
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// The rail that holds the card
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bottom_angle = 43.54;
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difference() {
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union() {
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translate([rail_depth, 0, -rail_flat_h]) rotate([0, 180+bottom_angle, 0]) cube([2, base[1]-side_wall, 2]);
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translate([-2+rail_depth, 0, -rail_flat_h]) cube([2, base[1]-side_wall, rail_flat_h]);
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}
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translate([-5+rail_depth, 0, 0]) cube([5, base[1]-side_wall, 5]);
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}
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pyramid_b = 3.23*sqrt(2);
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pyramid_t = 1.75*sqrt(2);
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pyramid_h = 1.0;
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pyramid_inset = 1.3+0.5;
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pyramid_step = 3.06;
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// The ramps to make slotting into the latch smooth
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translate([-1.75/2+pyramid_inset, 0, -1.75/2]) rotate([-90, 0, 0]) rotate([0, 0, 45]) {
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cylinder(r1 = pyramid_b/2, r2 = pyramid_t/2, h = pyramid_h, $fn=4);
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cylinder(r = pyramid_t/2, h = pyramid_step+pyramid_h, $fn=4);
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translate([-0.1, 0.1, 0])cylinder(r = pyramid_t/2, h = pyramid_step+pyramid_h, $fn=4);
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}
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latch_l = 2.67;
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latch_d = pyramid_inset;
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latch_h = 2.85;
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latch_wall = 1.39;
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// The pocket that the latch bar drops into, including a 45 degree cut for printability
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translate([0, latch_wall, -latch_h]) cube([latch_d, latch_l, latch_h]);
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if (make_printable) {
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translate([latch_d, latch_wall+latch_l, -latch_h]) rotate([0, 0, -180+45]) translate([0, -latch_l, 0]) cube([latch_d*2, latch_l, latch_h]);
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}
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}
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}
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// A simple cylinder cutout to fillet edges
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module fillet(radius, length) {
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translate([length, 0, 0]) rotate([0, -90, 0]) difference() {
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cube([radius, radius, length]);
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translate([radius, radius, -1]) cylinder(h = length+2, r = radius, $fn = 64);
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}
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}
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// The cutout for the USB-C plug
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module usb_c_cutout(open_top) {
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// The plug is "pushed in" by an extra 0.6 to account for 3d printing tolerances
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translate([-usb_c_w/2+usb_c_r, 7-10+0.6, usb_c_r]) rotate([-90, 0, 0]) union() {
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translate([0, usb_c_r, 0]) cylinder(r = usb_c_r, h = 10, $fn = 64);
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translate([usb_c_w-usb_c_r*2, usb_c_r, 0]) cylinder(r = usb_c_r, h = 10, $fn = 64);
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cube([usb_c_w-usb_c_r*2, usb_c_r*2, 10]);
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// Cutout for the pin side of the shell that expands out
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translate([0, usb_c_r, 0]) cylinder(r2 = usb_c_r, r1 = 3.84/2, h = 10-7.7, $fn = 64);
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translate([usb_c_w-usb_c_r*2, usb_c_r, 0]) cylinder(r2 = usb_c_r, r1 = 3.84/2, h = 10-7.7, $fn = 64);
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translate([usb_c_w/2-usb_c_r, usb_c_r, 0]) scale([1.8, 1, 1]) rotate([0, 0, 45]) cylinder(r2 = usb_c_r*sqrt(2), r1 = 3.84/2*sqrt(2), h = 10-7.7, $fn = 4);
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// If the card drops in from the top rather than sliding in from the front,
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// cut out a slot for the USB-C plug to drop into.
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if (open_top) {
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translate([-usb_c_r, -10+usb_c_r, 0]) cube([usb_c_w, 10, 10]);
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}
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}
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}
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// Quarter section of a sphere, used as a clip
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module qsphere(radius = 1) {
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difference() {
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sphere(r = radius, $fn = 32);
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translate([-radius-1, -radius-1, -radius]) cube([radius*2+2, radius*2+2, radius]);
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translate([0, -radius-1, -radius-1]) cube([radius, radius*2+2, radius*2+2]);
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}
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}
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// The screw boss for the PCB, optionally with space for a threaded insert
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module boss(radius, height = pcb_h, inner_size, make_printable) {
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difference() {
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cylinder(r = radius, h = height, $fn = 64);
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translate([0, 0, side_wall]) cylinder(r = inner_size/2, h = pcb_h, $fn = 64);
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}
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}
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module sma_hole() {
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radius = 3.15;
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rotate([90,0,0]) cylinder(h = side_wall,r = radius, $fn = 64);
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}
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// make expansion card lid
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module expansion_card_lid() {
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lower_lid_z = 0.6;
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ext_side_extension = 5;
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difference() {
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union() {
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// makes upper lid
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difference() {
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translate([-side_wall*2-gap, -base_ext[1]+side_wall+gap, base_ext[2]-side_wall]) cube([base_ext[0]-side_wall*2-gap*2, base_ext[1]-side_wall*2-gap*2, side_wall]);
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translate([-0.5,-16.4,8]) led_cylinder(); // hollow for D2 LED cylinder
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translate([30.55,-16.4,8]) led_cylinder(); // hollow for D3 LED cylinder
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}
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// joins them together
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translate([side_wall+gap, -side_wall, base[2]-lower_lid_z]) cube([base[0]-side_wall*2-gap*2, side_wall, base_ext[2]-base[2]+gap*2+0.1]);
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translate([side_wall+gap,-gap-side_wall,base_ext[2]-side_wall]) cube([base[0]-side_wall*2-gap*2, side_wall, side_wall]);
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// join on sma cover
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translate([-side_wall*2-gap,-base_ext[1],base_ext[2]-side_wall]) cube([base_ext[0]-side_wall*2-gap*2, side_wall+gap, side_wall]);
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// make sma cover half
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translate([-side_wall*2-gap, -base_ext[1], sma_height]) cube ([base_ext[0]-side_wall*2-gap*2, side_wall, base_ext[2]-sma_height]);
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// add screw holder to lid
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difference() {
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translate([-3.25,-base_ext[2]-side_wall-gap*3,sma_height]) cube([lid_wall_thickness, base_ext[2]+gap*2, base_ext[2]-sma_height-side_wall]);
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rotate([0,90,0]) translate([-base_ext[2]+3,-6,-3.25]) cylinder(r = lid_boss_r, h = 3, $fn = 64);
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translate([-0.5,-16.4,8]) led_cylinder(); // hollow for D2 LED cylinder
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}
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difference() {
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translate([base_ext[0]-3.25*2-side_wall*3-gap,-base_ext[2]-side_wall-gap*3,sma_height]) cube([lid_wall_thickness, base_ext[2]+gap*2, base_ext[2]-sma_height-side_wall]);
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rotate([0,90,0]) translate([-base_ext[2]+3,-6,base_ext[0]-2.5*2-side_wall*3-gap]) cylinder(r = lid_boss_r, h = 3, $fn = 64);
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translate([30.55,-16.4,8]) led_cylinder(); // hollow for D3 LED cylinder
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}
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}
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// make sma holes
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translate([sma-side_wall*2, -base_ext[2]-side_wall-side_wall/2+0.05, sma_height]) sma_hole();
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translate([base_ext[0]-sma-side_wall*4-gap*4, -base_ext[2]-side_wall-side_wall/2+0.05, sma_height]) sma_hole();
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}
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}
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// A basic, printable Expansion Card enclosure
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// open_end - A boolean to make the end of the card that is exposed when inserted open
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// make_printable - Adds ribs to improve printability
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// pcb_mount - The method the PCB is held in with, "boss" for self-threading screws,
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// "boss_insert" for fastener with a threaded insert,
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// "clip" for a fastener-less clip, or
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// "" for no PCB mounting structure
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module expansion_card_base(open_end, make_printable, pcb_mount="boss") {
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// Hollowing of the inside
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extra = 0.1;
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inner = [base[0]-side_wall*2, base[1]-side_wall*2, base[2]-side_wall+extra];
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ledge_fillet_r = 0.3;
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notch_l = 3.0;
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difference() {
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cube(base);
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difference() {
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notch = 1.0;
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notch_h = 3.8;
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// The main hollow
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translate([side_wall, 0, side_wall]) cube([inner[0], inner[1]+side_wall, inner[2]]);
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// Extra wall thickness where the latch cutouts are
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translate([side_wall, inner[1]+side_wall-notch_l, side_wall+notch_h/2]) rotate([0, 0, -90]) rotate([0, 90, 0]);
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translate([side_wall, inner[1]+side_wall-notch_l, side_wall]) cube([notch, notch_l, notch_h]);
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translate([inner[0]+side_wall, inner[1]+side_wall-notch_l, side_wall+notch_h/2]) rotate([0, 0, 180]) rotate([0, 90, 0]);
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translate([inner[0]+side_wall-notch, inner[1]+side_wall-notch_l, side_wall]) cube([notch, notch_l, notch_h]);
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}
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// cutout for sim card access
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translate([0,bay[1]-sim[1]/2+2.53,1.67]) cube(bay);
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// The rounded front edge to match the laptop
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edge_r = 0.8;
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// The USB-C plug cutout
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translate([base[0]/2, base[1], usb_c_r+usb_c_h]) usb_c_cutout(!open_end);
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// The sliding rails
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translate([0, base[1], rail_h]) rail(make_printable);
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translate([base[0], base[1], rail_h]) mirror([1, 0, 0]) rail(make_printable);
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// Cut out the end of what is normally the aluminum cover
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translate([0, base[1]-ledge_cut_d, 0]) cube([base[0], ledge_cut_d, ledge_cut]);
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// hollow bottom to provide room for back of board
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translate([side_wall,-notch_l,-hollow_bottom_z+1.5]) cube([base[0]-side_wall*2, base[1]-side_wall, hollow_bottom_z]);
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}
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difference() {
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// add extra bottom thickness to provide room for back of board
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translate([0,0,-hollow_bottom_z]) cube([base[0], base[1]-ledge_cut_d, bottom_thickness]);
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// engrave LES logo into bottom
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translate([base[0]-3, 17, -0.8]) rotate([0,180,0]) linear_extrude(height=bottom_thickness, center=true) {
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offset(0.01) import("LES.svg"); // the offset fixes a weird error about the svg's mesh being incomplete
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}
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// The fillets on the aluminum cover
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translate([base[0], base[1]-ledge_cut_d, -ledge_cut/2-hollow_bottom_z+0.3]) rotate([0, 0, 180]) fillet(ledge_cut/2, base[0]);
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}
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if (pcb_mount == "boss" || pcb_mount == "boss_insert") {
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// Add the screw bosses
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translate([boss_inc_x, boss_inc_y, 0]) boss(boss_r, pcb_h, 0, make_printable); // left int screwhole
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translate([base[0]-boss_inc_x, boss_inc_y, 0]) boss(boss_r, pcb_h, 0, make_printable); // right int screwhole
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} else if (pcb_mount == "clip") {
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clip_w = 1.5;
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clip_gap = 0.5;
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translate([boss_inc_x-boss_r, boss_inc_y-boss_r, 0]) {
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cube([boss_r*2, boss_r*2, pcb_h]);
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if (make_printable)
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translate([boss_r, boss_r*2, 0]) rib(boss_r*2, pcb_h);
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translate([0, boss_r-clip_w, pcb_h+pcb[2]+clip_gap]) rotate([0, 0, 180]) qsphere(clip_w);
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}
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translate([base[0]-boss_inc_x-boss_r, boss_inc_y-boss_r, 0]) {
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cube([boss_r*2, boss_r*2, pcb_h]);
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if (make_printable)
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translate([boss_r, boss_r*2, 0]) rib(boss_r*2, pcb_h);
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translate([boss_r*2, boss_r-clip_w, pcb_h+pcb[2]+clip_gap]) qsphere(clip_w);
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}
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}
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}
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module expansion_card_ext(make_printable, pcb_mount="boss_insert") {
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// Hollowing of the inside
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extra = 0.1;
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inner = [base_ext[0]-side_wall*2, base_ext[1]-side_wall*2, base_ext[2]-side_wall+extra];
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cutout = [base[0]-side_wall*2, base_ext[1]-side_wall*2, base_ext[2]-side_wall+extra];
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sma_cutout = [base_ext[0]-side_wall*2, base_ext[1]-side_wall*2, base_ext[2]];
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translate([boss_ext_x, boss_ext_y, 0]) boss(boss_ext_r, pcb_h, boss_ext_inner, make_printable); // left ext screwhole
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translate([base_ext[0]-boss_ext_x, boss_ext_y, 0]) boss(boss_ext_r, pcb_h, boss_ext_inner, make_printable); // right ext screwhole
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difference() {
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cube(base_ext);
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// cutout to bring base and ext card together
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// not sure why it needs 0.5mm added, rounding error maybe? <---- FIX THIS
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translate([base[0]-23.5, 5, side_wall]) cube([cutout[0], cutout[1], cutout[2]]);
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// half cut out for sma connectors
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translate([side_wall, 0-1, sma_height]) cube([sma_cutout[0], sma_cutout[1], sma_cutout[2]]);
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// sma holes
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translate([sma+side_wall+gap*2, side_wall, sma_height]) sma_hole();
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translate([base_ext[0]-sma-side_wall-gap*2, side_wall, sma_height]) sma_hole();
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// screw holes
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translate([0,base_ext[1]-boss_ext_top_y,base_ext[2]-boss_r-1.5]) rotate([0,90,0]) cylinder(r = 1, h = side_wall, $fn = 64);
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translate([base_ext[0]-side_wall,base_ext[1]-boss_ext_top_y,base_ext[2]-boss_r-1.5]) rotate([0,90,0]) cylinder(r = 1, h = side_wall, $fn = 64);
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difference() {
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// The main hollow
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translate([side_wall, side_wall, side_wall]) cube([inner[0], inner[1], inner[2]]);
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}
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// hollow bottom to provide room for back of board
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translate([(base_ext[0]-base[0])/2+side_wall,base_ext[1]-base_ext[1]/2+gap*2,-hollow_bottom_z+1.5]) cube([base[0]-side_wall*2, base_ext[1]/2, hollow_bottom_z]);
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}
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difference() {
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// add extra bottom thickness to provide room for back of board
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translate([(base_ext[0]-base[0])/2,base_ext[1]-base_ext[1]/2+side_wall-1,-hollow_bottom_z]) cube([base[0], (base_ext[1]/2)-side_wall+1, hollow_bottom_z]);
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translate([5, base_ext[1]-base_ext[1]/2+side_wall-0.001-1, -ledge_cut/2-hollow_bottom_z+0.3]) fillet(ledge_cut/2, base[0]);
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}
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}
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module sim_holder() {
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difference() {
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cube(sim);
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translate([0,bay[1]-sim[1]/2+1,0]) cube(bay);
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}
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}
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module led_cylinder(stopper) {
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if (stopper) { // if a stopper should be inserted
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cylinder(h = led_guide[1], r = led_guide[0], $fn = 64);
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translate([0,0,led_guide[1]-led_guide_stopper[1]-(base_ext[2]-sma_height)+0.03]) cylinder(h = led_guide_stopper[1], r = led_guide_stopper[0], $fn = 64);
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}
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else {
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cylinder(h = led_guide[1], r = led_guide[0], $fn = 64);
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}
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}
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translate([base_ext[0]-6.45-side_wall*2, -base[1]-base_ext[1]+side_wall*2+0.8, pcb_h+2.75]) led_cylinder(true); // D2 LED column
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translate([-0.5, -base[1]-base_ext[1]+side_wall*2+0.8, pcb_h+2.75]) led_cylinder(true); // D3 LED column
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translate([0, -base[1], 0]) expansion_card_base(open_end = false, make_printable = true, pcb_mount="boss");
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translate([-base_ext[0]+base[0]+5, -base_ext[1]-base[1], 0]) expansion_card_ext(make_printable = true, pcb_mount="boss");
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//translate([0, -32, 0]) expansion_card_lid();
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//translate([-128.75, 95.6, pcb_h]) import("PCB.stl");
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translate([2, -30.48, 1.68]) sim_holder();
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