From 4f56815cc62e75103ad9d43e4a52f38208e035d4 Mon Sep 17 00:00:00 2001
From: Bob - Home - Windows <rsheldiii@gmail.com>
Date: Sun, 3 Jun 2018 13:29:51 -0400
Subject: [PATCH] small changes to mold

---
 key_mold.scad | 101 ++++++++++++++++++++++++++++++--------------------
 1 file changed, 60 insertions(+), 41 deletions(-)

diff --git a/key_mold.scad b/key_mold.scad
index 67e9bac..17749f4 100644
--- a/key_mold.scad
+++ b/key_mold.scad
@@ -1,22 +1,28 @@
 
 include <keys.scad>
 
-//key unit size
-unit = 19.05 * 1.5;
+platform_width = 30;
+platform_height = 4;
+// height difference between bottom and top of platform
+platform_slant = 3;
 
-//height of keycap
-height = 13;
+minimum_height = 12;
 
 //minimum mold thickness
-extra = 12.5;
+extra = 9;
 
 //thicknesses of the mold
 side_thickness = 2;
 bottom_thickness = 2;
 
-total_side = unit + extra*2 + side_thickness * 2;
 
-bottom_box_height = 5;
+// computed variables
+inner_side = platform_width + extra * 2;
+total_side = inner_side + side_thickness * 2;
+
+
+// minimum_height of bottom, non-flared box
+bottom_box_height = 5 + bottom_thickness;
 
 function hypo(num) = sqrt(pow(num,2) / 2);
 
@@ -24,30 +30,30 @@ function hypo(num) = sqrt(pow(num,2) / 2);
 module bottom_box() {
   difference(){
     //outer box
-    cube([total_side, total_side, bottom_box_height + bottom_thickness]);
+    cube([total_side, total_side, bottom_box_height]);
 
     //inner box
     translate([ side_thickness, side_thickness, bottom_thickness]) {
-      cube([unit + extra*2, unit + extra*2, bottom_box_height + .02]);
+      cube([inner_side, inner_side, bottom_box_height - bottom_thickness + .02]);
     }
   }
 }
 
 module slanted_box() {
-  translate([total_side / 2, total_side / 2, bottom_box_height + bottom_thickness]) rotate([0,0,45]) difference(){
+  translate([total_side / 2, total_side / 2, bottom_box_height]) rotate([0,0,45]) difference(){
     //outer box
     cylinder(
-      height + extra - bottom_box_height + bottom_thickness * 4,
-      hypo(total_side),
-      hypo(total_side + 3),
+      h = minimum_height + extra - bottom_box_height + platform_height,
+      r1 = hypo(total_side),
+      r2 = hypo(total_side + 3),
       $fn=4
     );
 
     //inner box
     translate([0,0,-0.01]) cylinder(
-      height + extra - bottom_box_height + .02 + bottom_thickness * 4,
-      hypo(unit + extra*2),
-      hypo(unit + extra*2 + 3),
+      minimum_height + extra - bottom_box_height + .02 + platform_height,
+      hypo(inner_side),
+      hypo(inner_side + 3),
       $fn=4
     );
   }
@@ -55,51 +61,63 @@ module slanted_box() {
 
 module platform() {
   //platform
-  translate([
+  /* translate([
     side_thickness + extra,
     side_thickness + extra,
     bottom_thickness
-  ]) cube([unit, unit, bottom_thickness* 4]);
+  ]) cube([platform_width, platform_width, platform_height]); */
+
+  translate([
+    side_thickness + extra + platform_width/2,
+    side_thickness + extra + platform_width/2,
+    bottom_thickness
+  ]) rotate([0,0,45]) cylinder(r1=hypo(platform_width), r2=hypo(platform_width) - platform_slant, h=platform_height, $fn=4);
 }
 
 module registration() {
   positions = [
     [// bottom left
-      side_thickness + extra / 2,
-      side_thickness + extra / 2,
+      side_thickness + extra / 2 + 1,
+      side_thickness + extra / 2 + 1,
       bottom_thickness
     ],
     [// top left
-      side_thickness +  extra / 2,
-      side_thickness + unit + extra * 1.5,
+      side_thickness +  extra / 2 + 1,
+      side_thickness + platform_width + extra * 1.5 - 1,
       bottom_thickness
     ],
     [// bottom right
-      side_thickness + unit + extra * 1.5,
-      side_thickness +  extra / 2,
+      side_thickness + platform_width + extra * 1.5 - 1,
+      side_thickness +  extra / 2 + 1,
       bottom_thickness
     ],
     [// top right
-      side_thickness + unit + extra * 1.5,
-      side_thickness + unit + extra * 1.5,
+      side_thickness + platform_width + extra * 1.5 - 1,
+      side_thickness + platform_width + extra * 1.5 - 1,
       bottom_thickness
     ]
   ];
 
-  for (position = positions) {
-    translate(position) cylinder(3,extra/3, extra/4, $fn=4);
+  for (index = [0:len(positions)-1]) {
+    position = positions[index];
+    translate(position) {
+      // dont mind the math
+      rotate([0,0,45 / (index % 2 * 0.5 + 1)]) {
+        cylinder(platform_height / 2,extra/3, 2, $fn=(index % 2 * 2 + 4));
+      }
+    }
   }
 }
 
 module key_for_mold(wall_thickness = 20) {
   translate([
-    29,
-    29,
-    bottom_thickness * 5
+    total_side / 2,
+    total_side / 2,
+    platform_height + bottom_thickness
   ]) {
     $wall_thickness = wall_thickness;
     $support_type = false;
-    key();
+    sa_row(1) key();
   }
 }
 
@@ -117,7 +135,7 @@ module top_mold(){
     cube([
       total_side,
       total_side,
-      height + extra + bottom_thickness,
+      minimum_height + extra + bottom_thickness,
     ]);
 
     //inner box
@@ -127,21 +145,22 @@ module top_mold(){
       0
     ]) {
       cube([
-        unit + extra*2,
-        unit + extra*2,
-        height + extra + bottom_thickness,
+        inner_side,
+        inner_side,
+        minimum_height + extra + bottom_thickness,
       ]);
     }
   }
 }
 
-module skinner_box() {
+// for calculating how much mold material to use!
+module difference_box() {
   scale(.99) union() {
     cube([total_side, total_side, bottom_box_height + bottom_thickness]);
     translate([total_side / 2, total_side / 2, bottom_box_height + bottom_thickness]) rotate([0,0,45]){
       //outer box
       cylinder(
-        height + extra - bottom_box_height,
+        minimum_height + extra - bottom_box_height,
         hypo(total_side),
         hypo(total_side + 3),
         $fn=4
@@ -151,11 +170,11 @@ module skinner_box() {
 }
 
 difference() {
-  /* skinner_box(); */
+  /* difference_box(); */
 
-  bottom_mold();
+  /* bottom_mold(); */
 }
 
 /* key_for_mold(0); */
 
-/* translate([100,0,0]) top_mold(); */
+translate([0,0,0]) top_mold();