feat(flexmount): single mounting bridge

models/flexmount/flexmount.scad

@@ -9,9 +9,10 @@ fit_to_rack=true;
 
 /* [Device Measurements] */
 // Width of the device in mm. Will determine how far apart the actual mounts are in width.
-device_width=100; // TODO test for zero cube
+device_width=100
+; // TODO test for zero cube
 // Depth of the device in mm. Will determine how far apart the actual mounts are in depth.
-device_depth=99.0;
+device_depth=99;
 // Height of the device in mm. Will determine how far apart the actual mounts are in height.
 device_height=25.5;
 
@@ -27,40 +28,54 @@ TOLERANCE=0.2; // mm
 BASE_STRENGTH=2; // mm
 // Chamfer size. This is a sane default.
 CHAMFER=1; // mm
+// Lock Pin side length
+LOCK_PIN_SIDE=4; // mm
+// lock pin edge distance
+LOCK_PIN_EDGE_DISTANCE=5.5; // mm
 
 // diff_width resembles the gap between the device and the mount. This gap will be filled with a cuboid
-width_diff=( device_width + TOLERANCE ) % BASE_UNIT / 2;
-echo("Diff Width: ", width_diff);
-mount_anchor_left=device_width/2 + width_diff;
-echo("mount_anchor_left: ", mount_anchor_left);
+modulo_width=(BASE_UNIT - ( device_width + TOLERANCE ) % BASE_UNIT);
+WIDTH_DIFF = modulo_width==15 ? 0 : modulo_width;
+echo("Diff Width: ", WIDTH_DIFF);
 mount_gap_filler_start=(device_width+TOLERANCE)/2;
 echo("mount_gap_filler_start: ", mount_gap_filler_start);
-echo("mount_gap_filler_width: ", mount_anchor_left-mount_gap_filler_start);
-echo("effective mount distance: ", device_width+width_diff*2);
+echo("effective mount distance: ", device_width+WIDTH_DIFF+TOLERANCE);
+
+// diff_depth resembles the 
 
 /* Code */
 // creates a bracket around the device with TOLERANCE as additional space and BASE_STRENGTH as the strength of the bracket
 module bracket(width,depth,height) {
     // Bracket
+    outer_width=width+BASE_STRENGTH*2;
+    outer_depth=depth+BASE_STRENGTH*2;
+    outer_height=height+BASE_STRENGTH;
+    intersection(){
       difference() {
         // Outer
         cuboid(
-            size=[width+BASE_STRENGTH,depth+BASE_STRENGTH,height+BASE_STRENGTH],
+            size=[outer_width,outer_depth,outer_height],
             anchor=BOTTOM,
             chamfer=CHAMFER, edges=[TOP,FRONT,BACK,LEFT,RIGHT], except=[BOTTOM]
         );
         // Top Skeleton
         cuboid(
-            size=[width-BASE_STRENGTH*2,depth-BASE_STRENGTH*2,height+BASE_STRENGTH],
+            size=[width-BASE_STRENGTH*2,depth-BASE_STRENGTH*2,outer_height],
             anchor=BOTTOM,
             chamfer=-CHAMFER, edges=[TOP]
         );
         // Bottom Recess
         cuboid(
-          size=[width+BASE_STRENGTH,depth+BASE_STRENGTH,height-BASE_STRENGTH],
+          size=[outer_width,outer_depth,height-BASE_STRENGTH],
           anchor=BOTTOM
         );     
-        
+      }
+      translate([0,0,outer_height])
+      cuboid(
+        size=[outer_width,outer_depth,BASE_STRENGTH*2],
+        anchor=TOP,
+        chamfer=CHAMFER, edges=[BOTTOM]
+      );  
     }
 }
 
@@ -74,13 +89,14 @@ module device(width,depth,height) {
     );
 }
 
-module mount_rail(width,depth) {
+module mount_rail(width,depth,chamfer=CHAMFER) {
   difference(){
     height=BASE_UNIT+TOLERANCE/2;
     // outer
     cuboid(
       size=[width,depth,height],
-      anchor=TOP+LEFT
+      anchor=TOP+LEFT,
+      chamfer=chamfer, edges=[FRONT,BACK], except=[TOP,LEFT]
     );
     // support recess
     cuboid(
@@ -94,32 +110,66 @@ module mount_rail(width,depth) {
 // Mount
 module mount(){
   depth=BASE_UNIT+BASE_STRENGTH*2+TOLERANCE;
+  gap_filler_width=WIDTH_DIFF/2;
   union(){
-    translate([mount_gap_filler_start,0,0])
-    // Gap Filler
-    union(){
-      cuboid(
-        size=[width_diff,depth,device_height+BASE_STRENGTH],
-        anchor=BOTTOM+LEFT
-      );
-      mount_rail(width_diff,depth);
-    }
    
-    translate([mount_gap_filler_start+width_diff,0,0])
+    translate([mount_gap_filler_start,0,0])
 
     // Mount
+
+    // Mirror the mount to create a symmetric mount
+    
+    
+
     union(){
+
+      
+      top_width=BASE_STRENGTH;
+      bottom_width=BASE_UNIT+top_width+gap_filler_width;
+
       // Bridge
+      difference(){
+        cuboid_width = bottom_width-BASE_STRENGTH*2;
+        cuboid_chamfer = device_height < cuboid_width ? device_height : cuboid_width;
         prismoid(
-        size1 = [BASE_UNIT, depth],  // Bottom face: width 30, depth 60
-        size2 = [0, depth],   // Top face: becomes a line segment (width 0)
-        shift = [-BASE_UNIT/2, 0],   // Shift top edge center to X=+15 (aligns with right edge of base)
-        h = device_height+BASE_STRENGTH,             // Height
+          size1 = [bottom_width, depth],  // Bottom face: width 30, depth 60
+          size2 = [top_width, depth],   // Top face: becomes a line segment (width 0)
+          shift = [(-bottom_width+top_width)/2, 0],   // Shift top edge center to X=+15 (aligns with right edge of base)
+          chamfer=CHAMFER,
+          h = device_height,             // Height
+          //chamfer=CHAMFER/2,
           anchor = BOTTOM+LEFT // Anchor bottom left
         );
-      // Mount Rail
-      mount_rail(BASE_UNIT,depth);
+        translate([BASE_STRENGTH,0,BASE_STRENGTH])
+        cuboid(
+          size=[cuboid_width,BASE_UNIT,device_height],
+          anchor=BOTTOM+LEFT,
+          chamfer=cuboid_chamfer, edges=[LEFT], except=[TOP,RIGHT,FRONT,BACK]
+        );
       }
+
+      // Depth enforcement
+      depth_enforcement_x = BASE_STRENGTH-TOLERANCE/2;
+      prismoid(
+        size1 = [depth_enforcement_x, depth],  
+        size2 = [depth_enforcement_x, depth+BASE_UNIT],  
+        h = device_height,             
+        chamfer=[CHAMFER,0,0,CHAMFER],
+        anchor = BOTTOM+LEFT 
+      );
+      
+      // Mount Rail with holes
+      difference(){
+        mount_rail(bottom_width,depth);
+        // holes
+        translate([bottom_width-LOCK_PIN_EDGE_DISTANCE,0,-LOCK_PIN_EDGE_DISTANCE])
+        cuboid(
+          size=[LOCK_PIN_SIDE,depth,LOCK_PIN_SIDE],
+          anchor=TOP+RIGHT
+        );
+      }
+    }
+      
   }
 }