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@@ -5,10 +5,11 @@
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use <ee04.scad>
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/* [Preview] */
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-SHOW_BOARD = true;
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-SHOW_LID = true;
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-SHOW_BASE = true;
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-EXPLODE = 65; // mm to pull lid out in Y- for inspection (try 40)
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+SHOW_BOARD = true;
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+SHOW_LID = true;
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+SHOW_BASE = true;
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+SHOW_PLUNGERS = true;
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+EXPLODE = 65; // mm to pull lid out in Y- for inspection (try 40)
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/* [Board Dimensions — from EE04 STL] */
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PCB_L = 80.00; // board length (case_x axis)
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@@ -34,9 +35,15 @@ USBC_H = 4.8;
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USBC_CZ = 4.4;
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// ---- +Y wall: 3× user buttons + 1× reset ----
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-BTN_CX = [48.4, 39.1, 29.8, 20.4]; // PCB-relative case_x centres
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-BTN_D = 4.5;
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-BTN_CZ = 3.7;
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+BTN_CX = [48.4, 39.075, 29.725, 20.425]; // PCB-relative case_x centres
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+BTN_D = 2.3; // HOLE_D from hat.scad: PLUNGER_D(2.0) + 2×SLIP_CLEAR(0.15)
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+BTN_CZ = 3.85;
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+
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+/* [Plunger] */
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+PLUNGER_D = 2.0; // body and head diameter — matches button actuator
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+FLANGE_D = 2.9; // retention flange OD
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+FLANGE_T = 1.2; // flange thickness (axial)
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+PLUNGER_HEAD_H = 1.5; // exterior head protrusion past wall face
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/* [Case Parameters] */
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WALL = 2.0; // wall thickness
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@@ -61,7 +68,7 @@ PCB_BOSS_Y2 = PCB_W - 2.5;
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CLR_XN = 5.0; // X- side
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CLR_XP = 15.0; // X+ side (JST cable routing)
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CLR_YN = 15.0; // Y- side (FPC routing; lid inserts from here)
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-CLR_YP = 0.5; // Y+ side (snug against button/USB-C wall)
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+CLR_YP = 1.77; // Y+ side: calibrated contact(1.565) + rest clearance(0.20)
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CLR_LID = 5.0; // from tallest component top to lid underside
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/* [Sliding Lid] */
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@@ -116,6 +123,22 @@ module pcb_boss(px, py, stud=false) {
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}
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}
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+// Button plunger — origin at hole centre on the interior wall face.
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+// At rest: flange flush with interior face, head proud of exterior face.
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+module plunger() {
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+ color("orange") union() {
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+ translate([0, -FLANGE_T, 0])
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+ rotate([-90, 0, 0])
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+ cylinder(d = PLUNGER_D, h = FLANGE_T + WALL + PLUNGER_HEAD_H, $fn = 32);
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+ translate([0, -FLANGE_T, 0])
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+ rotate([-90, 0, 0])
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+ cylinder(d = FLANGE_D, h = FLANGE_T, $fn = 32);
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+ translate([0, WALL, 0])
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+ rotate([-90, 0, 0])
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+ cylinder(d = PLUNGER_D, h = PLUNGER_HEAD_H, $fn = 32);
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+ }
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+}
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+
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// ============================================================
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// BASE
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// ============================================================
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@@ -264,3 +287,8 @@ if (SHOW_LID)
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lid();
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if (SHOW_BOARD) stl_board();
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+
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+if (SHOW_PLUNGERS)
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+ for (bcx = BTN_CX)
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+ translate([PCB_OX + bcx, OUT_W - WALL, PCB_Z + BTN_CZ])
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+ plunger();
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