First try at manuform layout

1 files changed, 405 insertions, 0 deletions

diff --git a/src/dactyl_keyboard/dactyl-manuform.clj b/src/dactyl_keyboard/dactyl-manuform.clj
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+(ns dactyl-keyboard.dactyl
+  (:refer-clojure :exclude [use import])
+  (:require [scad-clj.scad :refer :all]
+            [scad-clj.model :refer :all]
+            [unicode-math.core :refer :all]))
+
+;;;;;;;;;;;;;;;;;
+;; Switch Hole ;;
+;;;;;;;;;;;;;;;;;
+
+(def keyswitch-height 14.4) ;; Was 14.1, then 14.25
+(def keyswitch-width 14.4)
+
+(def sa-profile-key-height 12.7)
+
+(def plate-thickness 4)
+(def mount-width (+ keyswitch-width 3))
+(def mount-height (+ keyswitch-height 3))
+
+(def single-plate
+  (let [top-wall (->> (cube (+ keyswitch-width 3) 1.5 plate-thickness)
+                      (translate [0
+                                  (+ (/ 1.5 2) (/ keyswitch-height 2))
+                                  (/ plate-thickness 2)]))
+        left-wall (->> (cube 1.5 (+ keyswitch-height 3) plate-thickness)
+                       (translate [(+ (/ 1.5 2) (/ keyswitch-width 2))
+                                   0
+                                   (/ plate-thickness 2)]))
+        side-nub (->> (binding [*fn* 30] (cylinder 1 2.75))
+                      (rotate (/ π 2) [1 0 0])
+                      (translate [(+ (/ keyswitch-width 2)) 0 1])
+                      (hull (->> (cube 1.5 2.75 plate-thickness)
+                                 (translate [(+ (/ 1.5 2) (/ keyswitch-width 2))
+                                             0
+                                             (/ plate-thickness 2)]))))
+        plate-half (union top-wall left-wall (with-fn 100 side-nub))]
+    (union plate-half
+           (->> plate-half
+                (mirror [1 0 0])
+                (mirror [0 1 0])))))
+
+;;;;;;;;;;;;;;;;
+;; SA Keycaps ;;
+;;;;;;;;;;;;;;;;
+
+(def sa-length 18.25)
+(def sa-double-length 37.5)
+(def sa-cap {1 (let [bl2 (/ 18.5 2)
+                     m (/ 17 2)
+                     key-cap (hull (->> (polygon [[bl2 bl2] [bl2 (- bl2)] [(- bl2) (- bl2)] [(- bl2) bl2]])
+                                        (extrude-linear {:height 0.1 :twist 0 :convexity 0})
+                                        (translate [0 0 0.05]))
+                                   (->> (polygon [[m m] [m (- m)] [(- m) (- m)] [(- m) m]])
+                                        (extrude-linear {:height 0.1 :twist 0 :convexity 0})
+                                        (translate [0 0 6]))
+                                   (->> (polygon [[6 6] [6 -6] [-6 -6] [-6 6]])
+                                        (extrude-linear {:height 0.1 :twist 0 :convexity 0})
+                                        (translate [0 0 12])))]
+                 (->> key-cap
+                      (translate [0 0 (+ 5 plate-thickness)])
+                      (color [220/255 163/255 163/255 1])))
+             2 (let [bl2 (/ sa-double-length 2)
+                     bw2 (/ 18.25 2)
+                     key-cap (hull (->> (polygon [[bw2 bl2] [bw2 (- bl2)] [(- bw2) (- bl2)] [(- bw2) bl2]])
+                                        (extrude-linear {:height 0.1 :twist 0 :convexity 0})
+                                        (translate [0 0 0.05]))
+                                   (->> (polygon [[6 16] [6 -16] [-6 -16] [-6 16]])
+                                        (extrude-linear {:height 0.1 :twist 0 :convexity 0})
+                                        (translate [0 0 12])))]
+                 (->> key-cap
+                      (translate [0 0 (+ 5 plate-thickness)])
+                      (color [127/255 159/255 127/255 1])))
+             1.5 (let [bl2 (/ 18.25 2)
+                       bw2 (/ 28 2)
+                       key-cap (hull (->> (polygon [[bw2 bl2] [bw2 (- bl2)] [(- bw2) (- bl2)] [(- bw2) bl2]])
+                                          (extrude-linear {:height 0.1 :twist 0 :convexity 0})
+                                          (translate [0 0 0.05]))
+                                     (->> (polygon [[11 6] [-11 6] [-11 -6] [11 -6]])
+                                          (extrude-linear {:height 0.1 :twist 0 :convexity 0})
+                                          (translate [0 0 12])))]
+                   (->> key-cap
+                        (translate [0 0 (+ 5 plate-thickness)])
+                        (color [240/255 223/255 175/255 1])))})
+
+;;;;;;;;;;;;;;;;;;;;;;;;;
+;; Placement Functions ;;
+;;;;;;;;;;;;;;;;;;;;;;;;;
+
+(def columns (range 0 6))
+(def rows (range 0 4))
+
+(def α (/ π 12))
+(def β (/ π 26))
+(def cap-top-height (+ plate-thickness sa-profile-key-height))
+(def row-radius (+ (/ (/ (+ mount-height 1/2) 2)
+                      (Math/sin (/ α 2)))
+                   cap-top-height))
+(def column-radius (+ (/ (/ (+ mount-width 2.0) 2)
+                         (Math/sin (/ β 2)))
+                      cap-top-height))
+
+(defn key-place [column row shape]
+  (let [row-placed-shape (->> shape
+                              (translate [0 0 (- row-radius)])
+                              (rotate (* α (- 1 row)) [1 0 0])      ; controls front-back tilt
+                              (translate [0 0 row-radius]))
+        column-offset (cond
+                        (= column 2) [0 2.82 -4.5]
+                        (>= column 4) [0 -5.8 5.64]
+                        :else [0 0 0])
+        column-angle (* β (- 3 column))     ; controls left-right tilt / tenting
+        placed-shape (->> row-placed-shape
+                          (translate [0 0 (- column-radius)])
+                          (rotate column-angle [0 1 0])
+                          (translate [0 0 column-radius])
+                          (translate column-offset))]
+    (->> placed-shape
+         (rotate (/ π 12) [0 1 0])
+         (translate [0 0 13]))))
+
+(defn case-place [column row shape]
+  (let [row-placed-shape (->> shape
+                              (translate [0 0 (- row-radius)])
+                              (rotate (* α (- 1 row)) [1 0 0])
+                              (translate [0 0 row-radius]))
+        column-offset [0 -4.35 5.64]
+        column-angle (* β (- 3 column))
+        placed-shape (->> row-placed-shape
+                          (translate [0 0 (- column-radius)])
+                          (rotate column-angle [0 1 0])
+                          (translate [0 0 column-radius])
+                          (translate column-offset))]
+    (->> placed-shape
+         (rotate (/ π 12) [0 1 0])
+         (translate [0 0 13]))))
+
+(def key-holes
+  (apply union
+         (for [column columns
+               row rows
+               :when (or (.contains [2 3] column)
+                         (not= row (last rows)))]
+           (->> single-plate
+                (key-place column row)))))
+
+(def caps
+  (apply union
+         (for [column columns
+               row rows
+               :when (or (.contains [2 3] column)
+                         (not= row (last rows)))]
+           (->> (sa-cap (if (= column 5) 1 1))
+                (key-place column row)))))
+
+;;;;;;;;;;;;;;;;;;;;
+;; Web Connectors ;;
+;;;;;;;;;;;;;;;;;;;;
+
+(def web-thickness 3.5)
+(def post-size 0.1)
+(def web-post (->> (cube post-size post-size web-thickness)
+                   (translate [0 0 (+ (/ web-thickness -2)
+                                      plate-thickness)])))
+
+(def post-adj (/ post-size 2))
+(def web-post-tr (translate [(- (/ mount-width 2) post-adj) (- (/ mount-height 2) post-adj) 0] web-post))
+(def web-post-tl (translate [(+ (/ mount-width -2) post-adj) (- (/ mount-height 2) post-adj) 0] web-post))
+(def web-post-bl (translate [(+ (/ mount-width -2) post-adj) (+ (/ mount-height -2) post-adj) 0] web-post))
+(def web-post-br (translate [(- (/ mount-width 2) post-adj) (+ (/ mount-height -2) post-adj) 0] web-post))
+
+(defn triangle-hulls [& shapes]
+  (apply union
+         (map (partial apply hull)
+              (partition 3 1 shapes))))
+
+(def connectors
+  (apply union
+         (concat
+          ;; Row connections
+          (for [column (drop-last columns)
+                row rows
+                :when (or (.contains [2] column)
+                          (not= row (last rows)))]
+            (triangle-hulls
+             (key-place (inc column) row web-post-tl)
+             (key-place column row web-post-tr)
+             (key-place (inc column) row web-post-bl)
+             (key-place column row web-post-br)))
+
+          ;; Column connections
+          (for [column columns
+                row (drop-last rows)
+            ;     :when (or (.contains [2 3] column)
+            ;               (not= row 2))
+                          ]
+            (triangle-hulls
+             (key-place column row web-post-bl)
+             (key-place column row web-post-br)
+             (key-place column (inc row) web-post-tl)
+             (key-place column (inc row) web-post-tr)))
+
+          ;; Diagonal connections
+          (for [column (drop-last columns)
+                row (drop-last rows)
+            ;     :when (or (.contains [ 1 2 3] column)
+            ;               (not= row 2))
+                          ]
+            (triangle-hulls
+             (key-place column row web-post-br)
+             (key-place column (inc row) web-post-tr)
+             (key-place (inc column) row web-post-bl)
+             (key-place (inc column) (inc row) web-post-tl))))))
+
+;;;;;;;;;;;;
+;; Thumbs ;;
+;;;;;;;;;;;;
+(def thumborigin [-25 -35 40])
+
+(defn deg2rad [degrees]
+  (* (/ degrees 180) pi))
+
+(defn thumb-a1-place [shape]
+  (->> shape
+       (rotate (deg2rad  10) [1 0 0])
+       (rotate (deg2rad -23) [0 1 0])
+       (rotate (deg2rad  -3) [0 0 1])
+       (translate thumborigin)
+       (translate [-16 -23 -3])
+       ))
+(defn thumb-a2-place [shape]
+  (->> shape
+       (rotate (deg2rad  15) [1 0 0])
+       (rotate (deg2rad -35) [0 1 0])
+       (rotate (deg2rad  54) [0 0 1])
+       (translate thumborigin)
+       (translate [-28 -50 -16])
+       ))
+(defn thumb-a3-place [shape]
+  (->> shape
+       (rotate (deg2rad   6) [1 0 0])
+       (rotate (deg2rad -34) [0 1 0])
+       (rotate (deg2rad  74) [0 0 1])
+       (translate thumborigin)
+       (translate [-35 -65 -27])))
+(defn thumb-b1-place [shape]
+  (->> shape
+       (rotate (deg2rad  10) [1 0 0])
+       (rotate (deg2rad -23) [0 1 0])
+       (rotate (deg2rad  -3) [0 0 1])
+       (translate thumborigin)
+       (translate [-36 -21 -5])))
+(defn thumb-b2-place [shape]
+  (->> shape
+       (rotate (deg2rad   6) [1 0 0])
+       (rotate (deg2rad -34) [0 1 0])
+       (rotate (deg2rad  70) [0 0 1])
+       (translate thumborigin)
+       (translate [-51 -34 -16])
+       ))
+(defn thumb-b3-place [shape]
+  (->> shape
+       (rotate (deg2rad   3) [1 0 0])
+       (rotate (deg2rad -35) [0 1 0])
+       (rotate (deg2rad  52) [0 0 1])
+       (translate thumborigin)
+       (translate [-55 -52 -28])
+       ))
+
+(defn thumb-1x-layout [shape]
+  (union
+   (thumb-a2-place shape)
+   (thumb-a3-place shape)
+   (thumb-b2-place shape)
+   (thumb-b3-place shape)))
+
+(defn thumb-15x-layout [shape]
+  (union
+   (thumb-a1-place shape)
+   (thumb-b1-place shape)))
+
+(def larger-plate
+  (let [plate-height (/ (- sa-double-length mount-height) 3)
+        top-plate (->> (cube mount-width plate-height web-thickness)
+                       (translate [0 (/ (+ plate-height mount-height) 2)
+                                   (- plate-thickness (/ web-thickness 2))]))
+        ]
+    (union top-plate (mirror [0 1 0] top-plate))))
+
+(def thumbcaps
+  (union
+   (thumb-1x-layout (sa-cap 1))
+   (thumb-15x-layout (rotate (/ π 2) [0 0 1] (sa-cap 1.5)))))
+
+(def thumb-connectors
+  (union
+   (apply union
+          (concat
+           (for [column [2] row [1]]
+             (triangle-hulls (thumb-place column row web-post-br)
+                             (thumb-place column row web-post-tr)
+                             (thumb-place (dec column) row web-post-bl)
+                             (thumb-place (dec column) row web-post-tl)))
+           (for [column [2] row [0 1]]
+             (triangle-hulls
+              (thumb-place column row web-post-bl)
+              (thumb-place column row web-post-br)
+              (thumb-place column (dec row) web-post-tl)
+              (thumb-place column (dec row) web-post-tr)))))
+   (let [plate-height (/ (- sa-double-length mount-height) 2)
+         thumb-tl (->> web-post-tl
+                       (translate [0 plate-height 0]))
+         thumb-bl (->> web-post-bl
+                       (translate [0 (- plate-height) 0]))
+         thumb-tr (->> web-post-tr
+                       (translate [0 plate-height 0]))
+         thumb-br (->> web-post-br
+                       (translate [0 (- plate-height) 0]))]
+     (union
+
+      ;;Connecting the two doubles
+      (triangle-hulls (thumb-place 0 -1/2 thumb-tl)
+                      (thumb-place 0 -1/2 thumb-bl)
+                      (thumb-place 1 -1/2 thumb-tr)
+                      (thumb-place 1 -1/2 thumb-br))
+
+      ;;Connecting the double to the one above it
+      (triangle-hulls (thumb-place 1 -1/2 thumb-tr)
+                      (thumb-place 1 -1/2 thumb-tl)
+                      (thumb-place 1 1 web-post-br)
+                      (thumb-place 1 1 web-post-bl))
+
+      ;;Connecting the 4 with the double in the bottom left
+      (triangle-hulls (thumb-place 1 1 web-post-bl)
+                      (thumb-place 1 -1/2 thumb-tl)
+                      (thumb-place 2 1 web-post-br)
+                      (thumb-place 2 0 web-post-tr))
+
+      ;;Connecting the two singles with the middle double
+      (hull (thumb-place 1 -1/2 thumb-tl)
+            (thumb-place 1 -1/2 thumb-bl)
+            (thumb-place 2 0 web-post-br)
+            (thumb-place 2 -1 web-post-tr))
+      (hull (thumb-place 1 -1/2 thumb-tl)
+            (thumb-place 2 0 web-post-tr)
+            (thumb-place 2 0 web-post-br))
+      (hull (thumb-place 1 -1/2 thumb-bl)
+            (thumb-place 2 -1 web-post-tr)
+            (thumb-place 2 -1 web-post-br))
+
+      ;;Connecting the thumb to everything
+      (triangle-hulls (thumb-place 0 -1/2 thumb-br)
+                      (key-place 1 4 web-post-bl)
+                      (thumb-place 0 -1/2 thumb-tr)
+                      (key-place 1 4 web-post-tl)
+                      (key-place 1 3 web-post-bl)
+                      (thumb-place 0 -1/2 thumb-tr)
+                      (key-place 0 3 web-post-br)
+                      (key-place 0 3 web-post-bl)
+                      (thumb-place 0 -1/2 thumb-tr)
+                      (thumb-place 0 -1/2 thumb-tl)
+                      (key-place 0 3 web-post-bl)
+                      (thumb-place 1 -1/2 thumb-tr)
+                      (thumb-place 1 1 web-post-br)
+                      (key-place 0 3 web-post-bl)
+                      (key-place 0 3 web-post-tl)
+                      (thumb-place 1 1 web-post-br)
+                      (thumb-place 1 1 web-post-tr))      
+      (hull (thumb-place 0 -1/2 web-post-tr)
+            (thumb-place 0 -1/2 thumb-tr)
+            (key-place 1 4 web-post-bl)
+            (key-place 1 4 web-post-tl))))))
+
+(def thumb
+  (union
+;    thumb-connectors
+   thumbcaps
+   (thumb-1x-layout single-plate)
+   (thumb-15x-layout single-plate)
+   (thumb-15x-layout larger-plate)
+   ))
+
+(spit "repl.scad"
+      (write-scad (union
+                   key-holes
+                   connectors
+                   caps
+                   thumb
+                  ;  thumbcaps
+                  ;  front-wall
+                  ;  right-wall
+                  ;  new-case
+                   )))
+
+;;;;;;;;;;
+;; Case ;;
+;;;;;;;;;;
+
+;; In column units
+(def right-wall-column (+ (last columns) 0.55))
+(def left-wall-column (- (first columns) 1/2))
+(def thumb-back-y 0.93)
+(def thumb-right-wall (- -1/2 0.05))
+(def thumb-front-row (+ -1 0.07))
+(def thumb-left-wall-column (+ 5/2 0.05))
+(def back-y 0.02)