OpenSCAD source code: Power supply brick mounting brackets for MPCNC

Power Supply Brick Mount.scad

// Power Supply Brick brackets
// Ed Nisley KE4ZNU 2018-02-26

Layout = "Show";

//-- Extrusion parameters

ThreadThick = 0.25;
ThreadWidth = 0.4;

HoleWindage = 0.3;      // enlarge hole dia by this amount

function IntegerMultiple(Size,Unit) = Unit * ceil(Size / Unit);

Protrusion = 0.1;    // make holes look good and joints intersect properly

//-- Useful sizes

inch = 25.4;

Tap10_32 = 0.159 * inch;
Clear10_32 = 0.190 * inch;
Head10_32 = 0.373 * inch;
Head10_32Thick = 0.110 * inch;
Nut10_32Dia = 0.433 * inch;
Nut10_32Thick = 0.130 * inch;

ID = 0;
OD = 1;
LENGTH = 2;

//-- Bracket Dimensions

Brick = [170.0,66.0,40.0];                      // overall size, add details in module

Socket = [30.0,24.0];                           // IEC power socket
Cable = [6.0,15.0];                             // DC output cable ID=wire OD=strain relief

WallThick = 3.0;                                // default wall thickness
BaseThick = 4.0;

Screw = [5.1,10.0,3.0];                         // screw size, more-or-less 10-32, OD & LENGTH for head

NumSides = 3*4;

//----------------------
// Useful routines

module PolyCyl(Dia,Height,ForceSides=0) {      // based on nophead's polyholes

  Sides = (ForceSides != 0) ? ForceSides : (ceil(Dia) + 2);

  FixDia = Dia / cos(180/Sides);

  cylinder(r=(FixDia + HoleWindage)/2,
           h=Height,
     $fn=Sides);
}

//----------------------
// Models



module BrickMount(End="Both") {

  difference() {
    union() {
      hull()                                      // main block
        for (i=[-1,1], j=[-1,1], k=[0,1])
          translate([i*(Brick.x/2 + WallThick - WallThick),
                    j*(Brick.y/2 + WallThick - WallThick),
                    k*(Brick.z + WallThick - WallThick)])
            sphere(r=WallThick,$fn=NumSides);
      hull()                                      // screw flanges
        for (i=[-1,1], j=[-1,1])
          translate([i*(Brick.x/2 + WallThick - BaseThick),
                    j*(Brick.y/2 + WallThick + 2*Screw[OD] - BaseThick),
                    0])
            sphere(r=BaseThick,$fn=NumSides);
    }
    for (i=[-1,1], j=[-1,1])                      // remove screw holes
      translate([i*(Brick.x/2 + WallThick - Screw[OD]),
                j*(Brick.y/2 + WallThick + Screw[OD]),
                -Protrusion])
        rotate(180/6)
          PolyCyl(Screw[ID],2*WallThick,6);

    translate([0,0,Brick.z/2])                    // remove center part to leave ends
      cube([(Brick.x + 2*WallThick - 4*Screw[OD]),2*Brick.y,2*Brick.z],center=true);

    if (End == "Socket")
      translate([Brick.x/2,0,Brick.z/2])                    // remove cable end to leave socket
        cube([(Brick.x + 2*WallThick - 4*Screw[OD]),2*Brick.y,2*Brick.z],center=true);

    if (End == "Cable")
      translate([-Brick.x/2,0,Brick.z/2])                    // remove socket end to leave cable
        cube([(Brick.x + 2*WallThick - 4*Screw[OD]),2*Brick.y,2*Brick.z],center=true);

    translate([0,0,Brick.z/2 - Protrusion/2])     // remove power supply brick from interior
      cube(Brick + [0,0,Protrusion],center=true);
    translate([0,0,-Brick.z])                     // remove below XY plane
      cube(2*Brick,center=true);

   translate([0,0,Brick.z/2])                     // remove AC socket
      rotate([0,-90,0])
        rotate(90)
        linear_extrude(height=Brick.x,convexity=2)
          square(Socket,center=true);

   translate([0,0,Brick.z/2])                     // remove DC cable
      rotate([0,90,0])
        rotate(180/8)
          PolyCyl(Cable[OD],Brick.x,8);
    translate([Brick.x/2,0,Brick.z/4 - Protrusion/2])            //  ... and wire slot
      cube([Brick.x,Cable[ID],Brick.z/2 + Protrusion],center=true);
  }

}

//----------------------
// Build it

if (Layout == "Show")
  BrickMount("Both");

if (Layout == "Build") {
  translate([5,0,Brick.x/2 + WallThick])
    rotate([0,90,0])
      BrickMount("Cable");
  translate([-5,0,Brick.x/2 + WallThick])
    rotate([0,-90,0])
      BrickMount("Socket");
}

More details on my blog at https://wp.me/poZKh-7nR