271 lines
12 KiB
OpenSCAD
271 lines
12 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 mini PCIe slot
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base_ext = [56.4, 33, 13];
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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_y = 10.5;
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boss_x = 4.2;
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boss_r = 2.95;
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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, use_insert, make_printable) {
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difference() {
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cylinder(r = radius, h = pcb_h, $fn = 64);
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translate([0, 0, side_wall]) cylinder(r = 1.25, h = pcb_h, $fn = 64);
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}
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}
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// Incomplete implementation of a lid to use with this shell
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module expansion_card_lid() {
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gap = 0.25;
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difference() {
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union() {
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// makes lower lid
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translate([side_wall+gap, side_wall+gap, base[2]-side_wall]) cube([base[0]-side_wall*2-gap*2, base[1]-side_wall*2-gap*2, side_wall]);
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// makes upper lid
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translate([base[0]-base_ext[0]+side_wall+gap, -base_ext[1]+2*(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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// joins them together
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translate([side_wall+gap,0,base_ext[2]-(base_ext[2]-base[2])-side_wall]) cube([base[0]-side_wall*2-gap*2, side_wall+gap, base_ext[2]-base[2]+side_wall]);
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difference() {
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translate([base[0]/2-usb_c_w/2+gap, base[1]-side_wall-gap, usb_c_r+usb_c_h]) cube([usb_c_w-gap*2, side_wall+gap, base[2]-(usb_c_r+usb_c_h)]);
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translate([base[0]/2, base[1], usb_c_r+usb_c_h]) usb_c_cutout(false);
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}
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// Adds screw holder to lid
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screw_holders();
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}
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// engrave LES logo into lid
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translate([3, 20, 7]) linear_extrude(height=1.5, 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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}
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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_insert") {
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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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difference() {
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cube(base);
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difference() {
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notch = 1.0;
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notch_l = 3.0;
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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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// 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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ledge_cut = 0.6;
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ledge_cut_d = 3.2;
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ledge_fillet_r = 0.3;
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translate([0, base[1]-ledge_cut_d, 0]) cube([base[0], ledge_cut_d, ledge_cut]);
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// The fillet on that cover
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translate([base[0], base[1]-ledge_cut_d, 0]) 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_x, boss_y, 0]) boss(boss_r, pcb_mount == "boss_insert", make_printable); // left int screwhole
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translate([base[0]-boss_x, boss_y, 0]) boss(boss_r, pcb_mount == "boss_insert", make_printable); // right int screwhole
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translate([base[0]-boss_x, boss_y-base_ext[1]-boss_y+2+2.2, 0]) boss(boss_r, pcb_mount == "boss_insert", make_printable); // right bottom ext screwhole
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translate([base[0]-base_ext[0]+boss_x, boss_y-base_ext[1]-boss_y+2+2.2, 0]) boss(boss_r, pcb_mount == "boss_insert", make_printable); // left bottom ext screwhole
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translate([base[0]-base_ext[0]+boss_x, base_ext[1]+boss_y-base_ext[1]-boss_y-2-2.2, 0]) boss(boss_r, pcb_mount == "boss_insert", make_printable); // left top ext screwhole
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translate([base[0]-boss_x, base_ext[1]+boss_y-base_ext[1]-boss_y-2-2.2, 0]) boss(boss_r, pcb_mount == "boss_insert", make_printable); // right top ext 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_x-boss_r, boss_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_x-boss_r, boss_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() {
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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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boss_r = 2.3;
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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?
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translate([base[0]-2.1, 5, side_wall]) cube([cutout[0], cutout[1], cutout[2]]);
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difference() {
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notch = 1.0;
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notch_l = 3.0;
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notch_h = 3.8;
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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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// 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]) rib(notch_h, notch);
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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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}
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}
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module screw_holders() {
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outline = [1,5,5];
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difference() {
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cube([outline[0],outline[1],outline[2]]);
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radius = 2;
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height = 10;
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rotate([0,90,0]) translate([(-outline[0]*2)-0.5,outline[1]/2, (outline[2]/2)-5]) cylinder(h = height,r = radius);
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}
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}
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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], -base_ext[1]-base[1], 0]) expansion_card_ext();
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translate([-60, -35, 0]) expansion_card_lid();
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