ghost-badge.jscad

const badgeWidth = 60;  // Really 54mm; extra wiggle for the folds.
const badgeHeight = 90;  // Really 85.55mm
const notchHeight = 3.5; // Really 2.5mm
const notchWidth = 14; // Really 12.5mm

const cornerRadius = 2;

// The wings hold the badge sides by being folded over along the Y axis.
const wingWidthRatio = 0.2;
const wingHeightRatio = 0.8;
const wingWidth = wingWidthRatio * badgeWidth;
const wingHeight = wingHeightRatio * badgeHeight;

// The flap holds the badge from below by being folded upwards along
// the X axis.
const flapHeightRatio = 1 - wingHeightRatio;
const flapWidthRatio = 1 - 2*wingWidthRatio;

function getParameterDefinitions() {
    return [
        { name: 'layer',
          type: 'choice',
          values: ['folds', 'outline'],
          captions: ['Mark (folds)', 'Cut (outline)'],
          caption: 'Layer to render',
        },
    ];
}

function main(params) {
    switch (params.layer) {
    case 'outline':
        return outline();
    case 'folds':
        return folds();
    default:
        throw 'Unexpected layer: ' + params.layer;
    }
}

function outline() {
    var o = [];
    o.push(roundedRectangle({
        corner1: [0, 0],
        corner2: [badgeWidth, badgeHeight],
        roundradius: cornerRadius,
    }));

    const leftWing = roundedRectangle({
        corner1: [-wingWidth, badgeHeight-wingHeight],
        corner2: [0, badgeHeight],
        roundradius: cornerRadius,
    });
    const rightWing = leftWing.mirroredX().translate([badgeWidth, 0, 0]);
    o.push(leftWing);
    o.push(rightWing);

    const flapHeight = flapHeightRatio * badgeHeight;
    const flap = roundedRectangle({
        corner1: [0, 0],
        corner2: [badgeWidth, -flapHeight],
        roundradius: cornerRadius,
    }).union(roundedRectangle({
        corner1: [wingWidth, -flapHeight],
        corner2: [badgeWidth-wingWidth, -badgeHeight],
        roundradius: cornerRadius,
        squareCorners: [0, 1],
        outerFilletCorners: [2,3],
    }));
    o.push(flap);

    const notchBaseWidth = badgeWidth - 2*wingWidth;
    const notchBaseHeight = notchHeight * 3;
    const notchBase = roundedRectangle({
        corner1: [0, 0],
        corner2: [notchBaseWidth, notchBaseHeight],
        squareCorners: [0, 1],
        outerFilletCorners: [0, 1],
        roundradius: cornerRadius,
    }).subtract(roundedRectangle({
        corner1: [(notchBaseWidth-notchWidth)/2, notchHeight],
        corner2: [(notchBaseWidth+notchWidth)/2, notchHeight * 2],
        roundradius: cornerRadius,
    }));
    
    o.push(notchBase.translate([(badgeWidth - notchBaseWidth) / 2, badgeHeight, 0]));
    o.push(notchBase.intersect(CAG.rectangle({
        // Shave off the outer fillets for the notch on the flap.
        corner1: [0, 0],
        corner2: [notchBaseWidth, notchBaseHeight],
    })).mirroredY().translate([(badgeWidth - notchBaseWidth) / 2, -badgeHeight, 0]));
    return o;
}


function folds() {
    var o = [];
    const wingFold = new CSG.Path2D([[0,badgeHeight-wingHeight+cornerRadius], [0, badgeHeight-cornerRadius]]).expandToCAG(0.5, 1);
    o.push(wingFold);
    o.push(wingFold.translate([badgeWidth, 0, 0]));

    o.push(new CSG.Path2D([[cornerRadius,0], [badgeWidth-cornerRadius, 0]]).expandToCAG(0.5, 1));
    return o;
}


// Delegate to CAG.roundedRectangle() but also:
// - fill in corners noted in params.squareCorners, specified as an
//   array of ints in 0..3, where 0 is lower-left and index increases
//   clockwise.
// - create fillets on the outside of outerFilletCorners (same corner
//   spec as above), where each fillet is 4 complements of
//   quarter-discs.
// These two enhancements make it easier to build up shapes from
// touching roundedRectangles without holes (squareCorners) and making
// interior joints smooth instead of sharp (outerFilletCorners).
roundedRectangle = function(params) {
    var rect = CAG.roundedRectangle(params);
    var bounds = rect.getBounds();
    var center = [(bounds[0].x + bounds[1].x)/2, (bounds[0].y + bounds[1].y)/2];
    // Corner i is given by [bounds[t].x, bounds[s].y] where [t,s] is
    // the i'th entry in this array.
    var cornersByIndex = [
        [0, 0],
        [1, 0],
        [1, 1],
        [0, 1]
    ];
    for (var c in params.squareCorners) {
        var cornerBoundsIndexes = cornersByIndex[params.squareCorners[c]];
        var corner = [bounds[cornerBoundsIndexes[0]].x, bounds[cornerBoundsIndexes[1]].y];
        rect = union(rect, CAG.rectangle({corner1: corner, corner2: center}));
    }
    for (var c in params.outerFilletCorners) {
        var cornerBoundsIndexes = cornersByIndex[params.outerFilletCorners[c]];
        var corner = [bounds[cornerBoundsIndexes[0]].x, bounds[cornerBoundsIndexes[1]].y];
        rect = union(rect, filletAt(corner, params.roundradius));
    }
    return rect;
}

// See description of outerFilletCorners above for what this is for.
filletAt = function(center, radius) {
    var c0 = [center[0] - radius, center[1] - radius];
    var c1 = [center[0] + radius, center[1] - radius];
    var c2 = [center[0] + radius, center[1] + radius];
    var c3 = [center[0] - radius, center[1] + radius];
    return CAG.rectangle({corner1: c0, corner2: c2}).subtract(
        union(
            CAG.circle({center: c0, radius: radius}),
            CAG.circle({center: c1, radius: radius}),
            CAG.circle({center: c2, radius: radius}),
            CAG.circle({center: c3, radius: radius})
        )
    );
}

ghost-badge.svg

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