Key plate screw holes and added key plate notches for snapping in switches rather than a giant undercut.

3 files changed, 97 insertions, 25 deletions

diff --git a/src/dactyl_manuform.py b/src/dactyl_manuform.py
index 0ad8e43..2753064 100644
--- a/src/dactyl_manuform.py
+++ b/src/dactyl_manuform.py
@@ -14,12 +14,13 @@ def rad2deg(rad: float) -> float:
     return rad * 180 / pi
 
 ENGINE = 'solid'
-ENGINE = 'cadquery'
+# ENGINE = 'cadquery'
 debug_exports = False
 
 # if __name__=='__main__':
 #
-
+from src.generate_configuration import *
+save_config()
 
 ## IMPORT DEFAULT CONFIG IN CASE NEW PARAMETERS EXIST
 import src.generate_configuration as cfg
@@ -50,20 +51,20 @@ lastcol = ncols - 1
 if plate_style in ['NUB', 'HS_NUB']:
     keyswitch_height = nub_keyswitch_height
     keyswitch_width = nub_keyswitch_width
-elif plate_style in ['UNDERCUT', 'HS_UNDERCUT']:
+elif plate_style in ['UNDERCUT', 'HS_UNDERCUT', 'NOTCH', 'HS_NOTCH']:
     keyswitch_height = undercut_keyswitch_height
     keyswitch_width = undercut_keyswitch_width
 else:
     keyswitch_height = hole_keyswitch_height
     keyswitch_width = hole_keyswitch_width
 
-if plate_style in ['HS_UNDERCUT', 'HS_NUB', 'HS_HOLE']:
+if 'HS_' in plate_style:
     symmetry = "asymmetric"
     plate_file = path.join("..", "src", r"hot_swap_plate")
     plate_offset = 0.0
 
-mount_width = keyswitch_width + 3
-mount_height = keyswitch_height + 3
+mount_width = keyswitch_width + 2 * plate_rim
+mount_height = keyswitch_height + 2 * plate_rim
 mount_thickness = plate_thickness
 
 if oled_mount_type is not None:
@@ -418,6 +419,7 @@ else:
 ####################################################
 
 
+
 def single_plate(cylinder_segments=100, side="right"):
 
     if plate_style in ['NUB', 'HS_NUB']:
@@ -448,17 +450,32 @@ def single_plate(cylinder_segments=100, side="right"):
         plate = box(mount_width, mount_height, mount_thickness)
         plate = translate(plate, (0.0, 0.0, mount_thickness / 2.0))
 
-        shape_cut = box(keyswitch_width, keyswitch_height, mount_thickness * 2)
-        shape_cut = translate(shape_cut, (0.0, 0.0, mount_thickness))
+        shape_cut = box(keyswitch_width, keyswitch_height, mount_thickness * 2 +.02)
+        shape_cut = translate(shape_cut, (0.0, 0.0, mount_thickness-.01))
 
         plate = difference(plate, [shape_cut])
 
-    if plate_style in ['UNDERCUT', 'HS_UNDERCUT']:
-        undercut = box(
-            keyswitch_width + 2 * clip_undercut,
-            keyswitch_height + 2 * clip_undercut,
-            mount_thickness
-        )
+    if plate_style in ['UNDERCUT', 'HS_UNDERCUT', 'NOTCH', 'HS_NOTCH']:
+        if plate_style in ['UNDERCUT', 'HS_UNDERCUT']:
+            undercut = box(
+                keyswitch_width + 2 * clip_undercut,
+                keyswitch_height + 2 * clip_undercut,
+                mount_thickness
+            )
+
+        if plate_style in ['NOTCH', 'HS_NOTCH']:
+            undercut = box(
+                notch_width,
+                keyswitch_height + 2 * clip_undercut,
+                mount_thickness
+            )
+            undercut = union([undercut,
+                box(
+                    keyswitch_width + 2 * clip_undercut,
+                    notch_width,
+                    mount_thickness
+                )
+            ])
 
         undercut = translate(undercut, (0.0, 0.0, -clip_thickness + mount_thickness / 2.0))
 
@@ -472,6 +489,32 @@ def single_plate(cylinder_segments=100, side="right"):
         socket = translate(socket, [0, 0, plate_thickness + plate_offset])
         plate = union([plate, socket])
 
+
+    if plate_holes:
+        half_width = plate_holes_width/2.
+        half_height = plate_holes_height/2.
+        x_off = plate_holes_xy_offset[0]
+        y_off = plate_holes_xy_offset[1]
+        holes = [
+            translate(
+                cylinder(radius=plate_holes_diameter/2, height=plate_holes_depth+.01),
+                (x_off+half_width, y_off+half_height, plate_holes_depth/2-.01)
+            ),
+            translate(
+                cylinder(radius=plate_holes_diameter / 2, height=plate_holes_depth+.01),
+                (x_off-half_width, y_off+half_height, plate_holes_depth/2-.01)
+            ),
+            translate(
+                cylinder(radius=plate_holes_diameter / 2, height=plate_holes_depth+.01),
+                (x_off-half_width, y_off-half_height, plate_holes_depth/2-.01)
+            ),
+            translate(
+                cylinder(radius=plate_holes_diameter / 2, height=plate_holes_depth+.01),
+                (x_off+half_width, y_off-half_height, plate_holes_depth/2-.01)
+            ),
+        ]
+        plate = difference(plate, holes)
+
     if side == "left":
         plate = mirror(plate, 'YZ')
 
@@ -2565,7 +2608,7 @@ def screw_insert_thumb(bottom_radius, top_radius, height):
 
     else:
         position = thumborigin()
-        position = list(np.array(position) + np.array([-25, -61, 0]))
+        position = list(np.array(position) + np.array([-21, -58, 0]))
         position[2] = 0
 
     shape = screw_insert_shape(bottom_radius, top_radius, height)
@@ -2813,9 +2856,12 @@ def run():
 
 
     base = baseplate()
-    export_file(shape=base, fname=path.join(r"..", "things", save_dir, config_name + r"_plate"))
-    export_dxf(shape=base, fname=path.join(r"..", "things", save_dir, config_name + r"_plate"))
+    export_file(shape=base, fname=path.join(r"..", "things", save_dir, config_name + r"_right_plate"))
+    export_dxf(shape=base, fname=path.join(r"..", "things", save_dir, config_name + r"_right_plate"))
 
+    lbase = mirror(base, 'YZ')
+    export_file(shape=lbase, fname=path.join(r"..", "things", save_dir, config_name + r"_left_plate"))
+    export_dxf(shape=lbase, fname=path.join(r"..", "things", save_dir, config_name + r"_left_plate"))
 
     if oled_mount_type == 'UNDERCUT':
         export_file(shape=oled_undercut_mount_frame()[1], fname=path.join(r"..", "things", save_dir, config_name + r"_oled_undercut_test"))
diff --git a/src/generate_configuration.py b/src/generate_configuration.py
index 3f5cd4f..3340214 100644
--- a/src/generate_configuration.py
+++ b/src/generate_configuration.py
@@ -84,9 +84,12 @@ shape_config = {
     # 'NUB' = original side nubs.
     # 'UNDERCUT' = snap fit undercut.  May require CLIP_THICKNESS and possibly CLIP_UNDERCUT tweaking
     #       and/or filing to get proper snap.
+    # 'NOTCH' = snap fit undercut only near switch clip.  May require CLIP_THICKNESS and possibly CLIP_UNDERCUT
+    #       tweaking and/or filing to get proper snap.
     # 'HS_NUB' = hot swap underside with nubs.
     # 'HS_UNDERCUT' = hot swap underside with undercut. Does not generate properly.  Hot swap step needs to be modified.
-    'plate_style':  'UNDERCUT',
+    # 'HS_NOTCH' = hot swap underside with notch.  Does not generate properly.  Hot swap step needs to be modified.
+    'plate_style':  'NOTCH',
 
     'hole_keyswitch_height':  14.0,
     'hole_keyswitch_width':  14.0,
@@ -94,12 +97,14 @@ shape_config = {
     'nub_keyswitch_height':  14.4,
     'nub_keyswitch_width':  14.4,
 
-    'undercut_keyswitch_height':  14.4,
-    'undercut_keyswitch_width':  14.4,
+    'undercut_keyswitch_height':  14.0,
+    'undercut_keyswitch_width':  14.0,
+    'notch_width': 5.0, # If using notch, it is identical to undecut, but only locally by the switch clip
 
     'sa_profile_key_height':  12.7,
-    'plate_thickness':  4,
+    'plate_thickness':  4+1.1,
 
+    'plate_rim': 1.5 + 0.5,
     # Undercut style dimensions
     'clip_thickness':  1.4,
     'clip_undercut':  1.0,
@@ -228,6 +233,16 @@ shape_config = {
     # Offset is from the top inner corner of the top inner key.
 
     ###################################
+    ## EXPERIMENTAL
+    ###################################
+    'plate_holes':  True,
+    'plate_holes_xy_offset': (0.0, 0.0),
+    'plate_holes_width': 14.3,
+    'plate_holes_height': 14.3,
+    'plate_holes_diameter': 1.7,
+    'plate_holes_depth': 20.0,
+
+    ###################################
     ## COLUMN OFFSETS
     ####################################
 
diff --git a/src/run_config.json b/src/run_config.json
index cf21a54..e1d3337 100644
--- a/src/run_config.json
+++ b/src/run_config.json
@@ -61,15 +61,17 @@
         17.5
     ],
     "fixed_tenting": 0.0,
-    "plate_style": "UNDERCUT",
+    "plate_style": "NOTCH",
     "hole_keyswitch_height": 14.0,
     "hole_keyswitch_width": 14.0,
     "nub_keyswitch_height": 14.4,
     "nub_keyswitch_width": 14.4,
-    "undercut_keyswitch_height": 14.4,
-    "undercut_keyswitch_width": 14.4,
+    "undercut_keyswitch_height": 14.0,
+    "undercut_keyswitch_width": 14.0,
+    "notch_width": 5.0,
     "sa_profile_key_height": 12.7,
-    "plate_thickness": 4,
+    "plate_thickness": 5.1,
+    "plate_rim": 2.0,
     "clip_thickness": 1.4,
     "clip_undercut": 1.0,
     "undercut_transition": 0.2,
@@ -173,6 +175,15 @@
     "base_rim_thickness": 5.0,
     "screw_cbore_diameter": 4.0,
     "screw_cbore_depth": 2.0,
+    "plate_holes": true,
+    "plate_holes_xy_offset": [
+        0.0,
+        0.0
+    ],
+    "plate_holes_width": 14.3,
+    "plate_holes_height": 14.3,
+    "plate_holes_diameter": 1.7,
+    "plate_holes_depth": 20.0,
     "column_offsets": [
         [
             0,