OpenSCAD Source Code: Halogen Lamp Base for Vacuum Tube Plate Cap Example

Vacuum Tube Lights.scad

// Vacuum Tube LED Lights
// Ed Nisley KE4ZNU January 2016

Layout = "LampBase";						// Show Build Cap LampBase USBPort

Section = true;							// cross-section the object

//- Extrusion parameters must match reality!

ThreadThick = 0.25;
ThreadWidth = 0.40;

HoleWindage = 0.2;

Protrusion = 0.1;			// make holes end cleanly

inch = 25.4;

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


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

Pixel = [7.0,10.0,3.0];								// ID = contact patch, OD = PCB dia, LENGTH = overall thickness


//----------------------
// 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);
}

//----------------------
// Tube cap

CapTube = [4.0,3/16 * inch,10.0];						// brass tube for flying lead to cap LED

CapSize = [Pixel[ID],(Pixel[OD] + 3.0),(CapTube[OD] + 2*Pixel[LENGTH])];

CapSides = 6*4;

module Cap() {
	
	difference() {
		union() {
			cylinder(d=CapSize[OD],h=(CapSize[LENGTH]),$fn=CapSides);		// main cap body
			translate([0,0,CapSize[LENGTH]])								// rounded top
				scale([1.0,1.0,0.65])
					sphere(d=CapSize[OD]/cos(180/CapSides),$fn=CapSides);	// cos() fixes slight undersize vs cylinder
			cylinder(d1=(CapSize[OD] + 2*3*ThreadWidth),d2=CapSize[OD],h=1.5*Pixel[LENGTH],$fn=CapSides);	// skirt
		}
		
		translate([0,0,-Protrusion])								// bore for wiring to LED
			PolyCyl(CapSize[ID],(CapSize[LENGTH] + 3*ThreadThick + Protrusion),CapSides);
			
		translate([0,0,-Protrusion])								// PCB recess with clearance for tube dome
			PolyCyl(Pixel[OD],(1.5*Pixel[LENGTH] + Protrusion),CapSides);
			
		translate([0,0,(1.5*Pixel[LENGTH] - Protrusion)])			// small step + cone to retain PCB
			cylinder(d1=(Pixel[OD]/cos(180/CapSides)),d2=Pixel[ID],h=(Pixel[LENGTH] + Protrusion),$fn=CapSides);
			
		translate([0,0,(CapSize[LENGTH] - CapTube[OD]/(2*cos(180/8)))])	// hole for brass tube holding wire loom
			rotate([90,0,0]) rotate(180/8)
				PolyCyl(CapTube[OD],CapSize[OD],8);
	}
	
}

//----------------------
// Aperture for USB-to-serial adapter snout
// These are all magic numbers, of course

module USBPort() {
	
	translate([0,28.0])
	rotate([90,0,0])
		linear_extrude(height=28.0)
			polygon(points=[
				[0,0],
				[8.0,0],
				[8.0,4.0],
//				[4.0,4.0],
				[4.0,6.5],
				[-4.0,6.5],
//				[-4.0,4.0],
				[-8.0,4.0],
				[-8.0,0],
			]);
}


//----------------------
// Box for Leviton ceramic lamp base

module LampBase() {
	
Bottom = 5.0;
Base = [3.75*inch,4.5*inch,25.0 + Bottom];
Sides = 12*4;

Stud = [0.107 * inch,15.0,Base[LENGTH]];			// 6-32 mounting screws, OD = ceramic boss size
StudOC = 3.5 * inch;
	
	union() {
		difference() {
			rotate(180/Sides)
				cylinder(d=Base[OD],h=Base[LENGTH],$fn=Sides);
			rotate(180/Sides)
				translate([0,0,Bottom])
					cylinder(d=Base[ID],h=Base[LENGTH],$fn=Sides);
			translate([0,-Base[OD]/2,Bottom + 1.2])				// mount on double-sided foam tape
				rotate(0)
					USBPort();
		}
		for (i = [-1,1])
			translate([i*StudOC/2,0,0])
				rotate(180/8)
					difference() {
						cylinder(d=Stud[OD],h=Stud[LENGTH],$fn=8);
						translate([0,0,Bottom])
							PolyCyl(Stud[ID],(Stud[LENGTH] - (Bottom - Protrusion)),6);
					}
	}
}


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

if (Layout == "Cap") {
	if (Section)
		difference() {
			Cap();
			translate([-CapSize[OD],0,CapSize[LENGTH]])
				cube([2*CapSize[OD],2*CapSize[OD],3*CapSize[LENGTH]],center=true);
		}
	else
		Cap();
}

if (Layout == "LampBase")
	LampBase();

if (Layout == "USBPort")
	USBPort();

if (Layout == "Build") {
	Cap();
	Spigot();
}

More details on my blog at http://wp.me/poZKh-5zC