Separable thumb improvements. PCB clearance cuts.

3 files changed, 229 insertions, 112 deletions

diff --git a/src/dactyl_manuform.py b/src/dactyl_manuform.py
index 0e79458..b68ffb4 100644
--- a/src/dactyl_manuform.py
+++ b/src/dactyl_manuform.py
@@ -273,6 +273,16 @@ def single_plate(cylinder_segments=100, side="right"):
 
     return plate
 
+def plate_pcb_cutout(side="right"):
+    shape = box(*plate_pcb_size)
+    shape = translate(shape, (0, 0, -plate_pcb_size[2]/2))
+    shape = translate(shape, plate_pcb_offset)
+
+    if side == "left":
+        shape = mirror(shape, 'YZ')
+
+    return shape
+
 def trackball_cutout(segments=100, side="right"):
     if trackball_modular:
         hole_diameter = ball_diameter + 2 * (ball_gap + ball_wall_thickness + trackball_modular_clearance+trackball_modular_lip_width)-.1
@@ -504,6 +514,19 @@ def key_holes(side="right"):
 
     return shape
 
+def plate_pcb_cutouts(side="right"):
+    debugprint('plate_pcb_cutouts()')
+    # hole = single_plate()
+    cutouts = []
+    for column in range(ncols):
+        for row in range(nrows):
+            if (column in [2, 3]) or (not row == lastrow):
+                cutouts.append(key_place(plate_pcb_cutout(side=side), column, row))
+
+    # cutouts = union(cutouts)
+
+    return cutouts
+
 
 def caps():
     caps = None
@@ -640,7 +663,7 @@ def thumborigin():
         origin[i] = origin[i] + thumb_offsets[i]
 
     if thumb_style == 'MINIDOX':
-        origin[1] = origin[1] - .4*(trackball_Usize-1)*sa_length
+        origin[1] = origin[1] - .4*(minidox_Usize-1)*sa_length
 
     return origin
 
@@ -720,6 +743,10 @@ def default_thumb_1x_layout(shape, cap=False):
         shapes = union(shape_list)
     return shapes
 
+def default_thumb_pcb_plate_cutouts(side="right"):
+    shape = default_thumb_1x_layout(plate_pcb_cutout(side=side))
+    shape = union([shape, default_thumb_15x_layout(plate_pcb_cutout(side=side))])
+    return shape
 
 def default_thumb_15x_layout(shape, cap=False, plate=True):
     debugprint('thumb_15x_layout()')
@@ -756,6 +783,9 @@ def default_thumb_15x_layout(shape, cap=False, plate=True):
 def adjustable_plate_size(Usize=1.5):
     return (Usize * sa_length - mount_height) / 2
 
+def usize_dimention(Usize=1.5):
+    return Usize * sa_length
+
 
 def adjustable_plate_half(Usize=1.5):
     debugprint('double_plate()')
@@ -771,6 +801,14 @@ def adjustable_plate(Usize=1.5):
     top_plate = adjustable_plate_half(Usize)
     return union((top_plate, mirror(top_plate, 'XZ')))
 
+def adjustable_square_plate(Uwidth=1.5, Uheight=1.5):
+    width = usize_dimention(Usize=Uwidth)
+    height = usize_dimention(Usize=Uheight)
+    print("width: {}, height: {}, thickness:{}".format(width, height, web_thickness))
+    shape = box(width, height, web_thickness)
+    shape = difference(shape, [box(mount_width-.01, mount_height-.01, 2*web_thickness)])
+    shape = translate(shape, (0, 0, web_thickness/2))
+    return shape
 
 def double_plate_half():
     debugprint('double_plate()')
@@ -864,6 +902,31 @@ def thumb_connectors(side='right', style_override=None):
         return default_thumb_connectors()
 
 
+def thumb_pcb_plate_cutouts(side='right', style_override=None):
+    if style_override is None:
+        _thumb_style = thumb_style
+    else:
+        _thumb_style = style_override
+
+    if _thumb_style == "MINI":
+        return mini_thumb_pcb_plate_cutouts(side)
+    elif _thumb_style == "MINIDOX":
+        return minidox_thumb_pcb_plate_cutouts(side)
+    elif _thumb_style == "CARBONFET":
+        return carbonfet_thumb_pcb_plate_cutouts(side)
+
+    elif "TRACKBALL" in _thumb_style:
+        if (side == ball_side or ball_side == 'both'):
+            if _thumb_style == "TRACKBALL_ORBYL":
+                return tbjs_thumb_pcb_plate_cutouts(side)
+            elif _thumb_style == "TRACKBALL_CJ":
+                return tbcj_thumb_pcb_plate_cutouts(side)
+        else:
+            return thumb_pcb_plate_cutouts(side, style_override=other_thumb)
+
+    else:
+        return default_thumb_pcb_plate_cutouts(side)
+
 def default_thumbcaps():
     t1 = default_thumb_1x_layout(sa_cap(1), cap=True)
     if not default_1U_cluster:
@@ -876,6 +939,7 @@ def default_thumb(side="right"):
     shape = default_thumb_1x_layout(rotate(single_plate(side=side), (0, 0, -90)))
     shape = union([shape, default_thumb_15x_layout(rotate(single_plate(side=side), (0, 0, -90)))])
     shape = union([shape, default_thumb_15x_layout(double_plate(), plate=False)])
+    shape = difference(shape, [default_thumb_pcb_plate_cutouts()])
     return shape
 
 
@@ -1130,6 +1194,11 @@ def mini_thumb(side="right"):
 
     return shape
 
+def mini_thumb_pcb_plate_cutouts(side="right"):
+    shape = mini_thumb_1x_layout(plate_pcb_cutout(side=side))
+    shape = union([shape, mini_thumb_15x_layout(plate_pcb_cutout(side=side))])
+    return shape
+
 
 def mini_thumb_post_tr():
     return translate(web_post(),
@@ -1321,9 +1390,11 @@ def minidox_thumb(side="right"):
     shape = minidox_thumb_fx_layout(rotate(single_plate(side=side), [0.0, 0.0, -90]))
     shape = union([shape, minidox_thumb_fx_layout(adjustable_plate(minidox_Usize))])
     # shape = minidox_thumb_1x_layout(single_plate(side=side))
+    return shape
 
-
-
+def minidox_thumb_pcb_plate_cutouts(side="right"):
+    shape = minidox_thumb_fx_layout(plate_pcb_cutout(side=side))
+    shape = union([shape, minidox_thumb_fx_layout(plate_pcb_cutout())])
     return shape
 
 def minidox_thumb_post_tr():
@@ -1484,6 +1555,11 @@ def carbonfet_thumb(side="right"):
 
     return shape
 
+def carbonfet_thumb_pcb_plate_cutouts(side="right"):
+    shape = carbonfet_thumb_1x_layout(plate_pcb_cutout(side=side))
+    shape = union([shape, carbonfet_thumb_15x_layout(plate_pcb_cutout())])
+    return shape
+
 def carbonfet_thumb_post_tr():
     return translate(web_post(),
         [(mount_width / 2) - post_adj, (mount_height / 1.15) - post_adj, 0]
@@ -1630,7 +1706,7 @@ def tbjs_thumb_position_rotation():
     rot = [10, -15, 5]
     pos = thumborigin()
     # Changes size based on key diameter around ball, shifting off of the top left cluster key.
-    shift = [-.9*tbjs_key_diameter/2+27-42, -.1*tbjs_key_diameter/2+3-20, -5]
+    shift = [-.9*tbjs_key_diameter/2+27-42, -.1*tbjs_key_diameter/2+3-25, -5]
     for i in range(len(pos)):
         pos[i] = pos[i] + shift[i] + tbjs_translation_offset[i]
 
@@ -1703,16 +1779,17 @@ def tbjs_thumb_1x_layout(shape):
         tbjs_thumb_br_place(rotate(shape, [0, 0, thumb_plate_br_rotation])),
     ])
 
+def tbjs_thumb_pcb_plate_cutouts(side="right"):
+    return tbjs_thumb_1x_layout(plate_pcb_cutout(side=side))
+
 
 def tbjs_thumb_fx_layout(shape):
-    return union([
-        # tbjs_thumb_tl_place(rotate(shape, [0, 0, thumb_plate_tr_rotation])),
-        # tbjs_thumb_tlold_place(rotate(shape, [0, 0, thumb_plate_tl_rotation])),
-        # tbjs_thumb_mlold_place(rotate(shape, [0, 0, thumb_plate_ml_rotation])),
-        # tbjs_thumb_mr_place(rotate(shape, [0, 0, thumb_plate_mr_rotation])),
-        # tbjs_thumb_bl_place(rotate(shape, [0, 0, thumb_plate_bl_rotation])),
-        # tbjs_thumb_br_place(rotate(shape, [0, 0, thumb_plate_br_rotation])),
-    ])
+    return [
+        tbjs_thumb_tl_place(rotate(shape, [0, 0, thumb_plate_tr_rotation])),
+        tbjs_thumb_mr_place(rotate(shape, [0, 0, thumb_plate_mr_rotation])),
+        tbjs_thumb_bl_place(rotate(shape, [0, 0, thumb_plate_bl_rotation])),
+        tbjs_thumb_br_place(rotate(shape, [0, 0, thumb_plate_br_rotation])),
+    ]
 
 def trackball_layout(shape):
     return union([
@@ -1722,14 +1799,16 @@ def trackball_layout(shape):
 
 def tbjs_thumbcaps():
     t1 = tbjs_thumb_1x_layout(sa_cap(1))
+    # t1 = tbjs_thumb_fx_layout(sa_cap(1))
     # t1.add(tbjs_thumb_15x_layout(rotate(sa_cap(1), [0, 0, rad2deg(pi / 2)])))
     return t1
 
 
 def tbjs_thumb(side="right"):
-    shape = tbjs_thumb_fx_layout(rotate(single_plate(side=side), [0.0, 0.0, -90]))
-    shape = union([shape, tbjs_thumb_fx_layout(double_plate())])
-    shape = union([shape, tbjs_thumb_1x_layout(single_plate(side=side))])
+    # shape = tbjs_thumb_fx_layout(rotate(single_plate(side=side), [0.0, 0.0, -90]))
+    shape = tbjs_thumb_1x_layout(single_plate(side=side))
+    # shape = tbjs_thumb_fx_layout(adjustable_square_plate(Uwidth=tbjs_Uwidth, Uheight=tbjs_Uheight))
+    shape = union([shape, *tbjs_thumb_fx_layout(adjustable_square_plate(Uwidth=tbjs_Uwidth, Uheight=tbjs_Uheight))])
 
     # shape = union([shape, trackball_layout(trackball_socket())])
     # shape = tbjs_thumb_1x_layout(single_plate(side=side))
@@ -1739,28 +1818,28 @@ def tbjs_thumb(side="right"):
 def tbjs_thumb_post_tr():
     debugprint('thumb_post_tr()')
     return translate(web_post(),
-                     [(mount_width / 2) - post_adj, ((mount_height/2) + adjustable_plate_size(trackball_Usize)) - post_adj, 0]
+                     [(mount_width / 2) + adjustable_plate_size(tbjs_Uwidth) - post_adj, ((mount_height/2) + adjustable_plate_size(tbjs_Uheight)) - post_adj, 0]
                      )
 
 
 def tbjs_thumb_post_tl():
     debugprint('thumb_post_tl()')
     return translate(web_post(),
-                     [-(mount_width / 2) + post_adj, ((mount_height/2) + adjustable_plate_size(trackball_Usize)) - post_adj, 0]
+                     [-(mount_width / 2) - adjustable_plate_size(tbjs_Uwidth) + post_adj, ((mount_height/2) + adjustable_plate_size(tbjs_Uheight)) - post_adj, 0]
                      )
 
 
 def tbjs_thumb_post_bl():
     debugprint('thumb_post_bl()')
     return translate(web_post(),
-                     [-(mount_width / 2) + post_adj, -((mount_height/2) + adjustable_plate_size(trackball_Usize)) + post_adj, 0]
+                     [-(mount_width / 2) - adjustable_plate_size(tbjs_Uwidth) + post_adj, -((mount_height/2) + adjustable_plate_size(tbjs_Uheight)) + post_adj, 0]
                      )
 
 
 def tbjs_thumb_post_br():
     debugprint('thumb_post_br()')
     return translate(web_post(),
-                     [(mount_width / 2) - post_adj, -((mount_height/2) + adjustable_plate_size(trackball_Usize)) + post_adj, 0]
+                     [(mount_width / 2) + adjustable_plate_size(tbjs_Uwidth) - post_adj, - ((mount_height/2) + adjustable_plate_size(tbjs_Uheight)) + post_adj, 0]
                      )
 
 
@@ -1821,21 +1900,21 @@ def tbjs_thumb_connectors():
         triangle_hulls(
             [
                 tbjs_place(tbjs_post_l()),
-                tbjs_thumb_bl_place(web_post_tl()),
+                tbjs_thumb_bl_place(tbjs_thumb_post_tl()),
                 tbjs_place(tbjs_post_bl()),
-                tbjs_thumb_bl_place(web_post_tr()),
-                tbjs_thumb_br_place(web_post_tl()),
+                tbjs_thumb_bl_place(tbjs_thumb_post_tr()),
+                tbjs_thumb_br_place(tbjs_thumb_post_tl()),
                 tbjs_place(tbjs_post_bl()),
-                tbjs_thumb_br_place(web_post_tr()),
+                tbjs_thumb_br_place(tbjs_thumb_post_tr()),
                 tbjs_place(tbjs_post_br()),
-                tbjs_thumb_br_place(web_post_tr()),
+                tbjs_thumb_br_place(tbjs_thumb_post_tr()),
                 tbjs_place(tbjs_post_br()),
-                tbjs_thumb_mr_place(web_post_br()),
+                tbjs_thumb_mr_place(tbjs_thumb_post_br()),
                 tbjs_place(tbjs_post_r()),
-                tbjs_thumb_mr_place(web_post_bl()),
-                tbjs_thumb_tl_place(web_post_br()),
+                tbjs_thumb_mr_place(tbjs_thumb_post_bl()),
+                tbjs_thumb_tl_place(tbjs_thumb_post_br()),
                 tbjs_place(tbjs_post_r()),
-                tbjs_thumb_tl_place(web_post_bl()),
+                tbjs_thumb_tl_place(tbjs_thumb_post_bl()),
                 tbjs_place(tbjs_post_tr()),
                 key_place(web_post_bl(), 0, cornerrow),
                 tbjs_place(tbjs_post_tl()),
@@ -1847,10 +1926,10 @@ def tbjs_thumb_connectors():
     hulls.append(
         triangle_hulls(
             [
-                tbjs_thumb_bl_place(web_post_tr()),
-                tbjs_thumb_br_place(web_post_tl()),
-                tbjs_thumb_bl_place(web_post_br()),
-                tbjs_thumb_br_place(web_post_bl()),
+                tbjs_thumb_bl_place(tbjs_thumb_post_tr()),
+                tbjs_thumb_br_place(tbjs_thumb_post_tl()),
+                tbjs_thumb_bl_place(tbjs_thumb_post_br()),
+                tbjs_thumb_br_place(tbjs_thumb_post_bl()),
             ]
         )
     )
@@ -1859,10 +1938,10 @@ def tbjs_thumb_connectors():
     hulls.append(
         triangle_hulls(
             [
-                tbjs_thumb_br_place(web_post_tr()),
-                tbjs_thumb_mr_place(web_post_br()),
-                tbjs_thumb_br_place(web_post_br()),
-                tbjs_thumb_mr_place(web_post_tr()),
+                tbjs_thumb_br_place(tbjs_thumb_post_tr()),
+                tbjs_thumb_mr_place(tbjs_thumb_post_br()),
+                tbjs_thumb_br_place(tbjs_thumb_post_br()),
+                tbjs_thumb_mr_place(tbjs_thumb_post_tr()),
             ]
         )
     )
@@ -1870,10 +1949,10 @@ def tbjs_thumb_connectors():
     hulls.append(
         triangle_hulls(
             [
-                tbjs_thumb_mr_place(web_post_bl()),
-                tbjs_thumb_tl_place(web_post_br()),
-                tbjs_thumb_mr_place(web_post_tl()),
-                tbjs_thumb_tl_place(web_post_tr()),
+                tbjs_thumb_mr_place(tbjs_thumb_post_bl()),
+                tbjs_thumb_tl_place(tbjs_thumb_post_br()),
+                tbjs_thumb_mr_place(tbjs_thumb_post_tl()),
+                tbjs_thumb_tl_place(tbjs_thumb_post_tr()),
             ]
         )
     )
@@ -1991,6 +2070,10 @@ def tbcj_thumb(side="right"):
     tb = tbcj_place(tbcj_holder())
     return union([t, tb])
 
+def tbcj_thumb_pcb_plate_cutouts(side="right"):
+    t = tbcj_thumb_layout(plate_pcb_cutout(side=side))
+    return t
+
 def tbcj_thumbcaps():
     t = tbcj_thumb_layout(sa_cap(1))
     return t
@@ -2512,21 +2595,21 @@ def tbjs_thumb_connection(side='right'):
         triangle_hulls(
             [
                 key_place(web_post_bl(), 0, cornerrow),
-                tbjs_thumb_tl_place(web_post_bl()),
+                tbjs_thumb_tl_place(tbjs_thumb_post_bl()),
                 key_place(web_post_br(), 0, cornerrow),
-                tbjs_thumb_tl_place(web_post_tl()),
+                tbjs_thumb_tl_place(tbjs_thumb_post_tl()),
                 key_place(web_post_bl(), 1, cornerrow),
-                tbjs_thumb_tl_place(web_post_tl()),
+                tbjs_thumb_tl_place(tbjs_thumb_post_tl()),
                 key_place(web_post_br(), 1, cornerrow),
-                tbjs_thumb_tl_place(web_post_tr()),
+                tbjs_thumb_tl_place(tbjs_thumb_post_tr()),
                 key_place(web_post_bl(), 2, lastrow),
-                tbjs_thumb_tl_place(web_post_tr()),
+                tbjs_thumb_tl_place(tbjs_thumb_post_tr()),
                 key_place(web_post_bl(), 2, lastrow),
-                tbjs_thumb_mr_place(web_post_tl()),
+                tbjs_thumb_mr_place(tbjs_thumb_post_tl()),
                 key_place(web_post_br(), 2, lastrow),
                 key_place(web_post_bl(), 3, lastrow),
-                tbjs_thumb_mr_place(web_post_tr()),
-                tbjs_thumb_mr_place(web_post_tl()),
+                tbjs_thumb_mr_place(tbjs_thumb_post_tr()),
+                tbjs_thumb_mr_place(tbjs_thumb_post_tl()),
                 key_place(web_post_br(), 2, lastrow),
 
             ]
@@ -2540,24 +2623,24 @@ def tbjs_thumb_walls():
     print('thumb_walls()')
     # thumb, walls
     shape = wall_brace(
-        tbjs_thumb_mr_place, .5, 1, web_post_tr(),
+        tbjs_thumb_mr_place, .5, 1, tbjs_thumb_post_tr(),
         (lambda sh: key_place(sh, 3, lastrow)), 0, -1, web_post_bl(),
     )
     shape = union([shape, wall_brace(
-        tbjs_thumb_mr_place, .5, 1, web_post_tr(),
-        tbjs_thumb_br_place, 0, -1, web_post_br(),
+        tbjs_thumb_mr_place, .5, 1, tbjs_thumb_post_tr(),
+        tbjs_thumb_br_place, 0, -1, tbjs_thumb_post_br(),
     )])
     shape = union([shape, wall_brace(
-        tbjs_thumb_br_place, 0, -1, web_post_br(),
-        tbjs_thumb_br_place, 0, -1, web_post_bl(),
+        tbjs_thumb_br_place, 0, -1, tbjs_thumb_post_br(),
+        tbjs_thumb_br_place, 0, -1, tbjs_thumb_post_bl(),
     )])
     shape = union([shape, wall_brace(
-        tbjs_thumb_br_place, 0, -1, web_post_bl(),
-        tbjs_thumb_bl_place, 0, -1, web_post_br(),
+        tbjs_thumb_br_place, 0, -1, tbjs_thumb_post_bl(),
+        tbjs_thumb_bl_place, 0, -1, tbjs_thumb_post_br(),
     )])
     shape = union([shape, wall_brace(
-        tbjs_thumb_bl_place, 0, -1, web_post_br(),
-        tbjs_thumb_bl_place, -1, -1, web_post_bl(),
+        tbjs_thumb_bl_place, 0, -1, tbjs_thumb_post_br(),
+        tbjs_thumb_bl_place, -1, -1, tbjs_thumb_post_bl(),
     )])
 
     shape = union([shape, wall_brace(
@@ -2570,11 +2653,11 @@ def tbjs_thumb_walls():
     )])
     shape = union([shape, wall_brace(
         tbjs_place, -1, 0, tbjs_post_l(),
-        tbjs_thumb_bl_place, -1, 0, web_post_tl(),
+        tbjs_thumb_bl_place, -1, 0, tbjs_thumb_post_tl(),
     )])
     shape = union([shape, wall_brace(
-        tbjs_thumb_bl_place, -1, 0, web_post_tl(),
-        tbjs_thumb_bl_place, -1, -1, web_post_bl(),
+        tbjs_thumb_bl_place, -1, 0, tbjs_thumb_post_tl(),
+        tbjs_thumb_bl_place, -1, -1, tbjs_thumb_post_bl(),
     )])
 
     return shape
@@ -3556,9 +3639,7 @@ def teensy_holder():
 def screw_insert_shape(bottom_radius, top_radius, height):
     debugprint('screw_insert_shape()')
     if bottom_radius == top_radius:
-        base = translate(cylinder(radius=bottom_radius, height=height),
-            (0, 0, -height / 2)
-        )
+        base = cylinder(radius=bottom_radius, height=height)
     else:
         base = translate(cone(r1=bottom_radius, r2=top_radius, height=height), (0, 0, -height / 2))
 
@@ -3703,23 +3784,25 @@ def thumb_screw_insert_holes(side='right'):
     )
 
 def thumb_screw_insert_outers(offset=0.0, side='right'):
-    bottom_radius = screw_insert_bottom_radius + 1.6
-    top_radius = screw_insert_top_radius + 1.6
+    # screw_insert_bottom_radius + screw_insert_wall
+    # screw_insert_top_radius + screw_insert_wall
+    bottom_radius = screw_insert_outer_radius
+    top_radius = screw_insert_outer_radius
     height = screw_insert_height + 1.5
-    return thumb_screw_insert(bottom_radius, top_radius, height, offset, side=side)
+    return thumb_screw_insert(bottom_radius, top_radius, height, offset=offset, side=side)
 
 def screw_insert_holes(side='right'):
     return screw_insert_all_shapes(
         screw_insert_bottom_radius, screw_insert_top_radius, screw_insert_height+.02, offset=-.01, side=side
     )
 
-def screw_insert_outers(side='right'):
-    return screw_insert_all_shapes(
-        screw_insert_bottom_radius + 1.6,
-        screw_insert_top_radius + 1.6,
-        screw_insert_height + 1.5,
-        side=side
-    )
+def screw_insert_outers(offset=0.0, side='right'):
+    # screw_insert_bottom_radius + screw_insert_wall
+    # screw_insert_top_radius + screw_insert_wall
+    bottom_radius = screw_insert_outer_radius
+    top_radius = screw_insert_outer_radius
+    height = screw_insert_height + 1.5
+    return screw_insert_all_shapes(bottom_radius, top_radius, height, offset=offset, side=side)
 
 def screw_insert_screw_holes(side='right'):
     return screw_insert_all_shapes(1.7, 1.7, 350, side=side)
@@ -3841,6 +3924,9 @@ def model_side(side="right"):
         if show_caps:
             shape = add([shape, ball])
 
+    if plate_pcb_clear:
+        shape = difference(shape, [plate_pcb_cutouts(side=side)])
+
     main_shape = shape
 
     #BUILD THUMB
@@ -3873,6 +3959,8 @@ def model_side(side="right"):
         thumb_section = difference(thumb_section, [tbcutout])
         thumb_section = union([thumb_section, sensor])
 
+    if plate_pcb_clear:
+        thumb_section = difference(thumb_section, [thumb_pcb_plate_cutouts(side=side)])
 
     block = box(350, 350, 40)
     block = translate(block, (0, 0, -20))
diff --git a/src/generate_configuration.py b/src/generate_configuration.py
index dfd5c67..bc7eb9e 100644
--- a/src/generate_configuration.py
+++ b/src/generate_configuration.py
@@ -44,7 +44,12 @@ shape_config = {
         11  # controls overall height# original=9 with centercol=3# use 16 for centercol=2
     ),
 
-    'web_thickness': 4.0,
+
+    'extra_width': 2.5,  # extra space between the base of keys# original= 2
+    'extra_height': 1.0,  # original= 0.5
+
+
+    'web_thickness': 4.0 + 1.1,
     'post_size': 0.1,
     # post_adj':  post_size / 2
     'post_adj': 0,
@@ -71,8 +76,8 @@ shape_config = {
     'minidox_separable_thumb_screw_xy_locations': [[-37, -34], [-62, 12], [10, -25]],
     'carbonfet_thumb_screw_xy_locations': [[-48, -37]],
     'carbonfet_separable_thumb_screw_xy_locations': [[-48, -37], [-52, 10], [12, -35]],
-    'orbyl_thumb_screw_xy_locations': [[-53, -60]],
-    'orbyl_separable_thumb_screw_xy_locations': [[-53, -60], [-67, 10], [8, -40]],
+    'orbyl_thumb_screw_xy_locations': [[-53, -68]],
+    'orbyl_separable_thumb_screw_xy_locations': [[-53, -68], [-66, 8], [10, -40]],
     'tbcj_thumb_screw_xy_locations': [[-40, -75]],
     'tbcj_separable_thumb_screw_xy_locations': [[-40, -75], [-63, 10], [15, -40]],
 
@@ -84,7 +89,6 @@ shape_config = {
     'thumb_plate_bl_rotation': 0.0,  # Bottom right plate rotation tweaks as thumb cluster is crowded for hot swap, etc.
     ##############################
     # EXPERIMENTAL
-
     'separable_thumb': True,  #creates a separable thumb section with additional screws to hold it down.  Only attached at base.
     ##############################
 
@@ -109,6 +113,9 @@ shape_config = {
     ##########################################
     'other_thumb': 'DEFAULT', # cluster used for second thumb except if ball_side == 'both'
     'tbjs_key_diameter': 70,
+    'tbjs_Uwidth': 1.2,  # size for inner key near trackball
+    'tbjs_Uheight': 1.2,  # size for inner key near trackball
+
     # Offsets are per key and are applied before rotating into place around the ball
     # X and Y act like Tangential and Radial around the ball
     # 'tbjs_translation_offset': (0, 0, 10),  # applied to the whole assy
@@ -145,8 +152,7 @@ shape_config = {
     'trackball_modular_ring_height': 10.0,  # height mount ring down from ball height. Covers gaps on elevated ball.
     'trackball_modular_clearance': 0.5,  # height of ball from ring, used to create identical position to fixed.
 
-    'trackball_Usize': 1.5,  # size for inner key near trackball
-    'ball_side': 'right', #'left', 'right', or 'both'
+    'ball_side': 'both', #'left', 'right', or 'both'
     'ball_diameter': 34.0,
     'ball_wall_thickness': 3,  # should not be changed unless the import models are changed.
     'ball_gap': 1.0,
@@ -169,9 +175,6 @@ shape_config = {
     ##############################
 
 
-    'extra_width':  2.5,  # extra space between the base of keys# original= 2
-    'extra_height':  1.0,  # original= 0.5
-
     'wall_z_offset':  15,  # length of the first downward_sloping part of the wall
     'wall_x_offset':  5,  # offset in the x and/or y direction for the first downward_sloping part of the wall (negative)
     'wall_y_offset':  6,  # offset in the x and/or y direction for the first downward_sloping part of the wall (negative)
@@ -225,11 +228,11 @@ shape_config = {
     'sa_profile_key_height':  12.7,
     'sa_length': 18.5,
     'sa_double_length': 37.5,
-    'plate_thickness':  4+1.1,
+    'plate_thickness':  4 + 1.1,
 
     'plate_rim': 1.5 + 0.5,
     # Undercut style dimensions
-    'clip_thickness':  1.4,
+    'clip_thickness':  1.3,
     'clip_undercut':  1.0,
     'undercut_transition':  .2,  # NOT FUNCTIONAL WITH OPENSCAD, ONLY WORKS WITH CADQUERY
 
@@ -327,11 +330,17 @@ shape_config = {
         }
     },
 
-    'screws_offset': 'INSIDE', #'OUTSIDE', 'INSIDE', 'ORIGINAL'
+    'screws_offset': 'INSIDE', # 'OUTSIDE', 'INSIDE', 'ORIGINAL'
 
     'screw_insert_height': 3.8,
-    'screw_insert_bottom_radius': 5.31 / 2,
-    'screw_insert_top_radius': 5.1 / 2,
+
+    # 'screw_insert_bottom_radius': 5.31 / 2,  #Designed for inserts
+    # 'screw_insert_top_radius': 5.1 / 2,  #Designed for inserts
+
+    'screw_insert_bottom_radius': 2.5 / 2,  # Designed for self tapping
+    'screw_insert_top_radius': 2.5 / 2,  # Designed for self tapping
+
+    'screw_insert_outer_radius': 4.25,  # Common to keep interface to base
 
     # Does anyone even use these?  I think they just get in the way.
     'wire_post_height': 7,
@@ -351,7 +360,7 @@ shape_config = {
     # 'USB_TEENSY' = Teensy holder, no RJ9
     # 'EXTERNAL' = square cutout for a holder such as the one from lolligagger.
     # 'NONE' = No openings in the back.
-    'controller_mount_type':  'PCB_MOUNT',
+    'controller_mount_type':  'EXTERNAL',
 
     'external_holder_height':  12.5,
     'external_holder_width':  28.75,
@@ -384,27 +393,34 @@ shape_config = {
     ## Bottom Plate Dimensions
     ###################################
     # COMMON DIMENSION
-    'screw_hole_diameter': 2,
+    'screw_hole_diameter': 3,
     # USED FOR CADQUERY ONLY
     'base_thickness': 3.0, # thickness in the middle of the plate
     'base_offset': 3.0, # Both start flat/flush on the bottom.  This offsets the base up (if positive)
     'base_rim_thickness': 5.0,  # thickness on the outer frame with screws
-    'screw_cbore_diameter': 4.0,
-    'screw_cbore_depth': 2.0,
+    'screw_cbore_diameter': 6.0,
+    'screw_cbore_depth': 2.5,
 
     # Offset is from the top inner corner of the top inner key.
 
     ###################################
     ## HOLES ON PLATE FOR PCB MOUNT
     ###################################
-    'plate_holes':  False,
+    '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_diameter': 1.6,
     'plate_holes_depth': 20.0,
 
     ###################################
+    ## EXPERIMENTAL
+    'plate_pcb_clear': False,
+    'plate_pcb_size': (18.5, 18.5, 5),
+    'plate_pcb_offset': (0, 0, 0),# this is off of the back of the plate size.
+    ###################################
+
+    ###################################
     ## SHOW PCB FOR FIT CHECK
     ###################################
     'pcb_width': 18.0,
diff --git a/src/run_config.json b/src/run_config.json
index 54c20bb..29f573a 100644
--- a/src/run_config.json
+++ b/src/run_config.json
@@ -20,7 +20,9 @@
         7
     ],
     "keyboard_z_offset": 11,
-    "web_thickness": 4.0,
+    "extra_width": 2.5,
+    "extra_height": 1.0,
+    "web_thickness": 5.1,
     "post_size": 0.1,
     "post_adj": 0,
     "thumb_style": "TRACKBALL_ORBYL",
@@ -101,20 +103,20 @@
     "orbyl_thumb_screw_xy_locations": [
         [
             -53,
-            -60
+            -68
         ]
     ],
     "orbyl_separable_thumb_screw_xy_locations": [
         [
             -53,
-            -60
+            -68
         ],
         [
-            -67,
-            10
+            -66,
+            8
         ],
         [
-            8,
+            10,
             -40
         ]
     ],
@@ -174,6 +176,8 @@
     ],
     "other_thumb": "DEFAULT",
     "tbjs_key_diameter": 70,
+    "tbjs_Uwidth": 1.2,
+    "tbjs_Uheight": 1.2,
     "tbjs_translation_offset": [
         0,
         0,
@@ -236,8 +240,7 @@
     "trackball_modular_ball_height": 3.0,
     "trackball_modular_ring_height": 10.0,
     "trackball_modular_clearance": 0.5,
-    "trackball_Usize": 1.5,
-    "ball_side": "right",
+    "ball_side": "both",
     "ball_diameter": 34.0,
     "ball_wall_thickness": 3,
     "ball_gap": 1.0,
@@ -268,8 +271,6 @@
     "pinky_1_5U": false,
     "first_1_5U_row": 0,
     "last_1_5U_row": 5,
-    "extra_width": 2.5,
-    "extra_height": 1.0,
     "wall_z_offset": 15,
     "wall_x_offset": 5,
     "wall_y_offset": 6,
@@ -322,7 +323,7 @@
     "sa_double_length": 37.5,
     "plate_thickness": 5.1,
     "plate_rim": 2.0,
-    "clip_thickness": 1.4,
+    "clip_thickness": 1.3,
     "clip_undercut": 1.0,
     "undercut_transition": 0.2,
     "plate_file": null,
@@ -430,12 +431,13 @@
     },
     "screws_offset": "INSIDE",
     "screw_insert_height": 3.8,
-    "screw_insert_bottom_radius": 2.655,
-    "screw_insert_top_radius": 2.55,
+    "screw_insert_bottom_radius": 1.25,
+    "screw_insert_top_radius": 1.25,
+    "screw_insert_outer_radius": 4.25,
     "wire_post_height": 7,
     "wire_post_overhang": 3.5,
     "wire_post_diameter": 2.6,
-    "controller_mount_type": "PCB_MOUNT",
+    "controller_mount_type": "EXTERNAL",
     "external_holder_height": 12.5,
     "external_holder_width": 28.75,
     "external_holder_xoffset": -5.0,
@@ -489,21 +491,32 @@
         22
     ],
     "pcb_screw_y_offset": -2,
-    "screw_hole_diameter": 2,
+    "screw_hole_diameter": 3,
     "base_thickness": 3.0,
     "base_offset": 3.0,
     "base_rim_thickness": 5.0,
-    "screw_cbore_diameter": 4.0,
-    "screw_cbore_depth": 2.0,
-    "plate_holes": false,
+    "screw_cbore_diameter": 6.0,
+    "screw_cbore_depth": 2.5,
+    "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_diameter": 1.6,
     "plate_holes_depth": 20.0,
+    "plate_pcb_clear": false,
+    "plate_pcb_size": [
+        18.5,
+        18.5,
+        5
+    ],
+    "plate_pcb_offset": [
+        0,
+        0,
+        0
+    ],
     "pcb_width": 18.0,
     "pcb_height": 18.0,
     "pcb_thickness": 1.5,