OpenSCAD source code: Frame holding square glass tiles over SK6812 LED PCBs

Glass Tile Frame.scad

// Illuminated Tile Grid
// Ed Nisley - KE4ZNU
// 2020-05

/* [Configuration] */

Layout = "Build";            // [Cell,CellArray,MCU,Base,Show,Build]

Shape = "Square";            // [Square, Pyramid, Cone]

Cells = [2,2];

CellDepth = 15.0;

Inserts = true;

SupportInserts = true;

/* [Hidden] */

ThreadThick = 0.25;
ThreadWidth = 0.40;

HoleWindage = 0.2;

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

Protrusion = 0.1;           // make holes end cleanly

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

Tile = [25.0 + 0.1,25.0 + 0.1,4.0];

WallThick = 4*ThreadWidth;
FloorThick = 3.0;

Flange = [2*ThreadWidth,2*ThreadWidth,0];               // ridge supporting tile

Separator = [3*ThreadWidth,3*ThreadWidth,Tile.z - 1];   // between tiles

Screw = [3.0,6.0,3.5];                                  // M3 SHCS, OD=head, LENGTH=head
Insert = [3.0,4.2,8.0];                                 // threaded brass insert

ScrewRecess = Screw[LENGTH] + 4*ThreadThick;

LEDPCB = [9.6,9.6,2.9];                                    // round SK6812, squared-off sides

LED = [5.0 + 2*HoleWindage,5.0 + 2*HoleWindage,1.3];

LEDOffset = [0.0,0.0,0.0];    // if offset from PCB center

CellOAL = [Tile.x,Tile.y,0] + Separator + [0,0,CellDepth] + [0,0,FloorThick];

ArrayOAL = [Cells.x*CellOAL.x,Cells.y*CellOAL.y,CellOAL.z];     // just the LED cells

BlockOAL = ArrayOAL + [2*WallThick,2*WallThick,0];              // LED cells + exterior wall
echo(str("Block OAL: ",BlockOAL));

InsertOC = ArrayOAL - [Insert[OD],Insert[OD],0] - [WallThick,WallThick,0];
echo(str("Insert OC: ",InsertOC));

TapeThick = 1.0;

Arduino = [44.0,18.0,8.0 + TapeThick];      // Arduino Nano to top of USB Mini-B plug
USBPlug = [15.0,11.0,9.0];      // USB Mini-B plug insulator
USBOffset = [0,0,5.0];          // offset from PCB base

WiringSpace = 3.5;
WiringBay = [(Cells.x - 1)*CellOAL.x + LEDPCB.x,(Cells.y - 1)*CellOAL.y + LEDPCB.x,WiringSpace];

PlateOAL = [BlockOAL.x,BlockOAL.y,FloorThick + Arduino.z + WiringSpace];   // allow wiring above Arduino
echo(str("Base Plate: ",PlateOAL));

echo(str("Screw length: ",(PlateOAL.z - ScrewRecess) + Insert.z/2," to ",(PlateOAL.z - ScrewRecess) + Insert.z));

LegendRecess = 1*ThreadThick;

//------------------------

module PolyCyl(Dia,Height,ForceSides=0) {      // based on nophead's polyholes
  Sides = (ForceSides != 0) ? ForceSides : (ceil(Dia) + 2);
  FixDia = Dia / cos(180/Sides);
  cylinder(d=(FixDia + HoleWindage),h=Height,$fn=Sides);
}


//-----------------------
// Base and optics in single tile

module LEDCone() {

  hull() {
    translate([0,0,CellDepth + Tile.z/2])
      cube(Tile - 2*[Flange.x,Flange.y,0],center=true);

    if (Shape == "Square") {
      translate([0,0,LEDPCB.z/2])
        cube([Tile.x,Tile.y,LEDPCB.z] - 2*[Flange.x,Flange.y,0],center=true);
    }
    else if (Shape == "Pyramid") {
      translate([0,0,LEDPCB.z/2])
        cube(LEDPCB,center=true);
    }
    else if (Shape == "Cone") {
      translate([0,0,LEDPCB.z/2])
        cylinder(d=1.0*LEDPCB.x,h=LED.z,center=true);
    }
    else {
      echo(str("Whoopsie! Invalid Shape: ",Shape));
      cube(5);
    }
  }
}

// One complete LED cell

module LEDCell() {

  difference() {

    translate([0,0,CellOAL.z/2])
      cube(CellOAL + [Protrusion,Protrusion,0],center=true);    // force overlapping adjacent sides!

    translate([0,0,CellOAL.z - Separator.z + Tile.z/2])
      cube(Tile,center=true);

    translate([0,0,LEDPCB.z])
      LEDCone();

//    cube([LED.x,LED.y,CellOAL.z],center=true);

    translate(-LEDOffset + [0,0,-CellOAL.z/2])
      rotate(180/8)
        PolyCyl(LEDPCB.x,CellOAL.z,8);
  }

}

// The whole array of cells

module CellArray() {
  difference() {
    union() {
      translate([CellOAL.x/2 - Cells.x*CellOAL.x/2,CellOAL.y/2 - Cells.y*CellOAL.y/2,0])
        for (i=[0:Cells.x - 1], j=[0:Cells.y - 1])
          translate([i*CellOAL.x,j*CellOAL.y,0])
            LEDCell();
      if (Inserts)      // bosses
        for (i=[-1,1], j=[-1,1])
          translate([i*InsertOC.x/2,j*InsertOC.y/2,0])
            rotate(180/8)
              cylinder(d=Insert[OD] + 2*WallThick,h=Insert[LENGTH],$fn=8);
    }
    if (Inserts)      // holes
      for (i=[-1,1], j=[-1,1])
        translate([i*InsertOC.x/2,j*InsertOC.y/2,-Protrusion])
          rotate(180/8)
            PolyCyl(Insert[OD],Insert[LENGTH] + FloorThick + Protrusion,8);

  }

  difference() {
    translate([0,0,CellOAL.z/2])
      cube(BlockOAL,center=true);
    translate([0,0,CellOAL.z])
      cube(ArrayOAL + [0,0,2*CellOAL.z],center=true);

  }
}

// Arduino bounding box
// Origin at center bottom of PCB

module Controller() {
  union() {
    translate([0,0,Arduino.z/2])
      cube(Arduino,center=true);
    translate([Arduino.x/2 - Protrusion,-USBPlug.y/2,USBOffset.z + TapeThick - USBPlug.z/2])
      cube(USBPlug + [Protrusion,0,0],center=false);
  }
}

// Baseplate

module BasePlate() {

  difference() {
    translate([0,0,PlateOAL.z/2])
      cube(PlateOAL,center=true);

    translate([PlateOAL.x/2 - Arduino.x/2 - 2*WallThick,0,FloorThick])
      Controller();

    translate([PlateOAL.x/2 - Arduino.x/2 - 2*WallThick,0,FloorThick + PlateOAL.z/2])
      cube([Arduino.x - 2*2.0,WiringBay.y,PlateOAL.z],center=true);   // cutouts beside MCU

    translate([0,0,PlateOAL.z - WiringBay.z + PlateOAL.z/2 - Protrusion])
      cube([PlateOAL.x - 2*WallThick,WiringBay.y,PlateOAL.z],center=true);    // cutout above MCU
    translate([0,0,PlateOAL.z - WiringBay.z + PlateOAL.z/2 - Protrusion])
      cube([WiringBay.x,PlateOAL.y - 2*WallThick,PlateOAL.z],center=true);    // cutout above MCU


    if (Inserts)
      for (i=[-1,1], j=[-1,1])
        translate([i*InsertOC.x/2,j*InsertOC.y/2,-Protrusion])
          rotate(180/8) {
            PolyCyl(Screw[ID],2*PlateOAL.z,8);
            PolyCyl(Screw[OD],ScrewRecess + Protrusion,8);
          }

    cube([45,17.0,2*LegendRecess],center=true);
  }

  linear_extrude(height=2*LegendRecess) {
    translate([0,1])
      rotate(-0*90) mirror([1,0,0])
        text(text="Ed Nisley",size=6,font="Arial:style:Bold",halign="center");
    translate([0,-6.5])
      rotate(-0*90) mirror([1,0,0])
        text(text="softsolder.com",size=4.5,font="Arial:style:Bold",halign="center");
  }

  Fin = [Screw[OD]/2 - 1.5*ThreadWidth,2*ThreadWidth,ScrewRecess - ThreadThick];
  if (Inserts && SupportInserts)
    color("Yellow")
      for (i=[-1,1], j=[-1,1])
        translate([i*InsertOC.x/2,j*InsertOC.y/2,0]) {
          rotate(180/8)
            cylinder(d=6*ThreadWidth,h=ThreadThick,$fn=8);
          for (a=[0:90:360])
              rotate(a)
                translate([Fin.x/2 + ThreadWidth/2,0,(ScrewRecess - ThreadThick)/2])
                  cube(Fin,center=true);
        }
}


//-----------------------
// Build things

if (Layout == "Cell")
  LEDCell();

else if (Layout == "CellArray")
  CellArray();

else if (Layout == "MCU")
  Controller();

else if (Layout == "Base")
  BasePlate();

else if (Layout == "Show") {
  translate([0,0,3*PlateOAL.z])
    CellArray();
  BasePlate();
  translate([PlateOAL.x/2 - Arduino.x/2 - 2*WallThick,0,FloorThick])
    color("Orange",0.3)
      Controller();
}

else if (Layout == "Build") union() {
  translate([0,0.6*BlockOAL.y,0])
    CellArray();
  translate([0,-0.6*BlockOAL.x,0])
    rotate(90)
      BasePlate();
}

More details on my blog at https://wp.me/poZKh-98y