path: root/src/dactyl_keyboard/dactyl-manuform.clj

(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]))


(def nrows 4)
(def lastrow (dec nrows))
(def cornerrow (dec lastrow))

;;;;;;;;;;;;;;;;;
;; 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 nrows))

(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 lastrow))]
           (->> single-plate
                (key-place column row)))))

(def caps
  (apply union
         (for [column columns
               row rows
               :when (or (.contains [2 3] column)
                         (not= row lastrow))]
           (->> (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 lastrow))]
            (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 [-23 -34 35])

(defn deg2rad [degrees]
  (* (/ degrees 180) pi))

(defn thumb-tr-place [shape]
  (->> shape
       (rotate (deg2rad  10) [1 0 0])
       (rotate (deg2rad -23) [0 1 0])
       (rotate (deg2rad  -3) [0 0 1])
       (translate thumborigin)
       (translate [-10 -16 0])
       ))
(defn thumb-tl-place [shape]
  (->> shape
       (rotate (deg2rad  10) [1 0 0])
       (rotate (deg2rad -23) [0 1 0])
       (rotate (deg2rad  -3) [0 0 1])
       (translate thumborigin)
       (translate [-30 -15 -2])))
(defn thumb-mr-place [shape]
  (->> shape
       (rotate (deg2rad  -6) [1 0 0])
       (rotate (deg2rad -34) [0 1 0])
       (rotate (deg2rad  48) [0 0 1])
       (translate thumborigin)
       (translate [-29 -40 -13])
       ))
(defn thumb-ml-place [shape]
  (->> shape
       (rotate (deg2rad   6) [1 0 0])
       (rotate (deg2rad -34) [0 1 0])
       (rotate (deg2rad  40) [0 0 1])
       (translate thumborigin)
       (translate [-51 -25 -12])))
(defn thumb-br-place [shape]
  (->> shape
       (rotate (deg2rad -16) [1 0 0])
       (rotate (deg2rad -33) [0 1 0])
       (rotate (deg2rad  54) [0 0 1])
       (translate thumborigin)
       (translate [-37.8 -55.3 -25.3])
       ))
(defn thumb-bl-place [shape]
  (->> shape
       (rotate (deg2rad  -4) [1 0 0])
       (rotate (deg2rad -35) [0 1 0])
       (rotate (deg2rad  52) [0 0 1])
       (translate thumborigin)
       (translate [-56.3 -43.3 -23.5])
       ))

(defn thumb-1x-layout [shape]
  (union
   (thumb-mr-place shape)
   (thumb-ml-place shape)
   (thumb-br-place shape)
   (thumb-bl-place shape)))

(defn thumb-15x-layout [shape]
  (union
   (thumb-tr-place shape)
   (thumb-tl-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
  (union
   (thumb-1x-layout single-plate)
   (thumb-15x-layout single-plate)
   (thumb-15x-layout larger-plate)
   ))

(def thumb-post-tr (translate [(- (/ mount-width 2) post-adj)  (- (/ mount-height  1.15) post-adj) 0] web-post))
(def thumb-post-tl (translate [(+ (/ mount-width -2) post-adj) (- (/ mount-height  1.15) post-adj) 0] web-post))
(def thumb-post-bl (translate [(+ (/ mount-width -2) post-adj) (+ (/ mount-height -1.15) post-adj) 0] web-post))
(def thumb-post-br (translate [(- (/ mount-width 2) post-adj)  (+ (/ mount-height -1.15) post-adj) 0] web-post))

(def thumb-connectors
  (union
      (triangle-hulls    ; top two
             (thumb-tl-place thumb-post-tr)
             (thumb-tl-place thumb-post-br)
             (thumb-tr-place thumb-post-tl)
             (thumb-tr-place thumb-post-bl))
      (triangle-hulls    ; bottom two on the right
             (thumb-br-place web-post-tr)
             (thumb-br-place web-post-br)
             (thumb-mr-place web-post-tl)
             (thumb-mr-place web-post-bl))
      (triangle-hulls    ; bottom two on the left
             (thumb-bl-place web-post-tr)
             (thumb-bl-place web-post-br)
             (thumb-ml-place web-post-tl)
             (thumb-ml-place web-post-bl))
      (triangle-hulls    ; centers of the bottom four
             (thumb-br-place web-post-tl)
             (thumb-bl-place web-post-bl)
             (thumb-br-place web-post-tr)
             (thumb-bl-place web-post-br)
             (thumb-mr-place web-post-tl)
             (thumb-ml-place web-post-bl)
             (thumb-mr-place web-post-tr)
             (thumb-ml-place web-post-br))
      (triangle-hulls    ; top two to the middle two, starting on the left
             (thumb-tl-place thumb-post-tl)
             (thumb-ml-place web-post-tr)
             (thumb-tl-place thumb-post-bl)
             (thumb-ml-place web-post-br)
             (thumb-tl-place thumb-post-br)
             (thumb-mr-place web-post-tr)
             (thumb-tr-place thumb-post-bl)
             (thumb-mr-place web-post-br)
             (thumb-tr-place thumb-post-br)) 
      (triangle-hulls    ; top two to the main keyboard, starting on the left
             (thumb-tl-place thumb-post-tl)
             (key-place 0 cornerrow web-post-bl)
             (thumb-tl-place thumb-post-tr)
             (key-place 0 cornerrow web-post-br)
             (thumb-tr-place thumb-post-tl)
             (key-place 1 cornerrow web-post-bl)
             (key-place 1 cornerrow web-post-br)
             (thumb-tr-place thumb-post-tr)
             (key-place 2 cornerrow web-post-tl)
             (key-place 2 cornerrow web-post-bl)
      )
  ))

(spit "repl.scad"
      (write-scad (union
                   key-holes
                   connectors
                   thumb
                   thumb-connectors
                  ;  thumbcaps
                   caps
                  ;  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)