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OpenSCAD source code: Cell array for WS2812 RGB LED breakout PCB and 25 mm glass tile
// 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;
Support = true;
Inserts = 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 = 3*ThreadWidth;
Flange = [4*ThreadWidth,4*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
PCB = [15.0,8.0,2.5];
LED = [5.0 + 2*HoleWindage,5.0 + 2*HoleWindage,1.0];
LEDOffset = [0.0,(PCB.y - LED.y)/2 - 0.5,0.0]; // slight offset from +Y PCB edge
CellOAL = [Tile.x,Tile.y,0] + Separator + [0,0,CellDepth] + [0,0,WallThick] + [0,0,PCB.z];
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] - [2*WallThick,2*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 = [15.0,11.0,8.5]; // USB Mini-B plug insulator
USBOffset = [0,0,5.5]; // offset from PCB base
WiringBay = [BlockOAL.x - 4*WallThick,38.0,3.0];
PlateOAL = [BlockOAL.x,BlockOAL.y,WallThick + Arduino.z + WiringBay.z];
echo(str("Base Plate: ",PlateOAL));
//------------------------
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,$fn=Sides);
}
//-----------------------
// Base and optics in single tile
module LEDCone() {
hull() {
translate([0,0,CellDepth + Tile.z/2])
cube(Tile - [Flange.x,Flange.y,0],center=true);
if (Shape == "Square") {
translate([0,0,LED.z/2])
cube([Tile.x,Tile.y,LED.z] - [Flange.x,Flange.y,0],center=true);
}
else if (Shape == "Pyramid") {
translate([0,0,LED.z/2])
cube(LED,center=true);
}
else if (Shape == "Cone") {
translate([0,0,LED.z/2])
cylinder(d=1.5*LED.x,h=LED.z,center=true);
}
else {
echo(str("Whoopsie! Invalid Shape: ",Shape));
cube(5);
}
}
}
// One complete LED cell
module LEDCell() {
difference() {
translate([0,0,CellOAL.z/2])
cube(CellOAL,center=true);
translate([0,0,CellOAL.z - Separator.z + Tile.z/2])
cube(Tile,center=true);
translate([0,0,PCB.z + WallThick])
LEDCone();
cube([LED.x,LED.y,CellOAL.z],center=true);
translate(-LEDOffset + [0,0,PCB.z/2 - Protrusion/2])
cube(PCB + [0,0,Protrusion],center=true);
}
if (Support)
color("Yellow") render()
translate(-LEDOffset) {
// translate([0,0,ThreadThick/2])
// cube([PCB.x - 2*ThreadWidth,PCB.y - 2*ThreadWidth,ThreadThick],center=true);
intersection() {
translate([0,0,(PCB.z - ThreadThick)/2])
cube([PCB.x - 2*ThreadWidth,PCB.y - 2*ThreadWidth,PCB.z - ThreadThick],center=true);
union() { for (a=[0:22.5:359])
rotate(a)
translate([PCB.x/2,0,PCB.z/2])
cube([PCB.x,2*ThreadWidth,PCB.z],center=true); }
}
}
}
// The whole array of cells
module CellArray() {
difference() {
union() {
translate([CellOAL.x/2 - Cells.x*CellOAL.x/2,CellOAL.y/2 - Cells.y*CellOAL.y/2,0])
for (i=[0:Cells.x - 1], j=[0:Cells.y - 1])
translate([i*CellOAL.x,j*CellOAL.y,0])
LEDCell();
if (Inserts) // bosses
for (i=[-1,1], j=[-1,1])
translate([i*InsertOC.x/2,j*InsertOC.y/2,0])
rotate(180/8)
cylinder(d=Insert[OD] + 3*WallThick,h=Insert[LENGTH],$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] + WallThick + 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([0,0,WallThick])
Controller();
translate([0,0,WallThick + PlateOAL.z/2])
cube([Arduino.x - 2*2.0,WiringBay.y,PlateOAL.z],center=true);
translate([0,0,PlateOAL.z - WiringBay.z + WiringBay.z/2])
cube(WiringBay + [0,0,2*Protrusion],center=true);
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],Screw[LENGTH] + 4*ThreadThick + Protrusion,8);
}
translate([0,0,ThreadThick-Protrusion])
cube([17.0,45,2*ThreadThick],center=true);
}
linear_extrude(height=2*ThreadWidth + Protrusion) {
translate([1,0,-Protrusion])
rotate(-90) mirror([1,0,0])
text(text="Ed Nisley",size=6,font="Arial:style:Bold",halign="center");
translate([-6.5,0,-Protrusion])
rotate(-90) mirror([1,0,0])
text(text="softsolder.com",size=4.5,font="Arial:style:Bold",halign="center");
}
if (Support)
color("Yellow")
for (i=[-1,1], j=[-1,1])
translate([i*InsertOC.x/2,j*InsertOC.y/2,0])
for (a=[0:45:135])
rotate(a)
translate([0,0,(Screw[LENGTH] - ThreadThick)/2])
cube([Screw[OD] - 2*ThreadWidth,2*ThreadWidth,Screw[LENGTH] - ThreadThick],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,PlateOAL.z + 10])
CellArray();
BasePlate();
}
else if (Layout == "Build") {
translate([0,0.6*BlockOAL.y,0])
CellArray();
translate([0,-0.6*BlockOAL.y,0])
rotate(90)
BasePlate();
}
@ednisley

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ednisley commented May 25, 2020

More details on my blog at https://wp.me/poZKh-95M

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