epaper_door_case/epd_case.scad

// GDEY0583T81 — Waveshare 5.83" ePaper Display Case
use <GDEY0583T81.scad>
// Display slides in from Y-; no Y- side wall
// FPC cable exits toward Y+ then bends 90° toward Z- through backplate slot

// --- Display Dimensions ---
DISP_W = 125.4;   // overall width  (X)
DISP_D = 99.5;    // overall depth  (Y)
DISP_T = 1.2;     // thickness      (Z)

// --- Active (Visible) Area ---
ACT_W  = 118.78;  // active area width (X)
ACT_D  = 88.22;   // active area depth (Y)

// --- Case Parameters ---
WALL     = 2.0;   // wall and backplate thickness
LIP      = 1.5;   // front bezel lip thickness (Z, sits on top of display)
TOL      = 0.3;   // per-side clearance for display fit (0.3 mm suits FDM sliding tolerances)
CHAM       = 1.0;   // chamfer Z height at window opening
CHAM_ANGLE = 60;    // chamfer face angle from vertical (deg); 45 = equal bevel, lower = less overhang
CORNER_R = 2.5;   // XY corner fillet radius (matches EE04 case)
BEZEL_Y    = 2.5;   // extra Y- bezel beyond the display's natural 3.30 mm border
EXPLODE    = 0;    // mm to pull display mockup toward Y- in preview
SHOW_DISP  = true; // show GDEY0583T81 mockup in preview
FPC_BEND_R = 4.0;  // FPC cable bend radius toward Z- (starting at display Y+ edge)
CLIP_Z     = 0;     // preview-only: mm to remove from Z+ (0 = full model; LIP reveals cavity; LIP+DISP_T reveals floor)

// --- Derived Dimensions ---
cav_w    = DISP_W + TOL * 2;
cav_d    = DISP_D + TOL;       // tolerance on Y+ side only; Y- is open
case_w   = cav_w + WALL * 2;
case_h   = WALL + DISP_T + LIP;

// FPC slot geometry — cable dims from 583.scad (12.5 mm wide, 0.3 mm thick;
//   right edge 55.47 mm from display right edge)
_fpc_x1  = WALL + TOL + DISP_W - 55.47 - 12.50 - 2.5;  // slot left edge (2.5 mm wider each side)
_fpc_xw  = 12.50 + 5.0;                                  // slot width (5 mm wider than cable)
_fpc_ro  = FPC_BEND_R + 0.30 + TOL;               // outer clearance radius (bend_r + fpc_t + tol)
// max Y reached by arc at Z=0 (backplate bottom); drives minimum case_d
_bend_my = BEZEL_Y + DISP_D + sqrt(_fpc_ro*_fpc_ro - (FPC_BEND_R - WALL)*(FPC_BEND_R - WALL));
case_d   = max(cav_d + WALL + BEZEL_Y, _bend_my + WALL);

_cham_xy = CHAM * tan(CHAM_ANGLE);  // horizontal expansion derived from angle

// Active window position in case coordinates
// X: symmetric (3.31 mm border each side)
// Y: offset per drawing — 3.30 mm from Y- entry edge, 7.98 mm from Y+ (FPC) edge
win_x  = WALL + TOL + (DISP_W - ACT_W) / 2;
win_y  = 3.30 + BEZEL_Y;

module rounded_box(l, w, h, r) {
    hull()
        for (dx = [r, l-r], dy = [r, w-r])
            translate([dx, dy, 0]) cylinder(r=r, h=h, $fn=32);
}

module epd_case() {
    difference() {
        // Solid case body — open at Y=0 (no Y- wall) by construction
        rounded_box(case_w, case_d, case_h, CORNER_R);

        // Display cavity: slides in from Y=0; BEZEL_Y extends depth so display seats at Y=BEZEL_Y
        translate([WALL, -0.01, WALL])
            cube([cav_w, BEZEL_Y + cav_d + 0.01, DISP_T + TOL]);

        // Active area window: straight portion + chamfered top edges
        // Extends 0.01 mm into the display cavity to avoid a coplanar face with the mockup
        translate([win_x, win_y, WALL + DISP_T - 0.01])
            cube([ACT_W, ACT_D, LIP - CHAM + 0.02]);
        hull() {
            translate([win_x, win_y, case_h - CHAM])
                cube([ACT_W, ACT_D, 0.01]);
            translate([win_x - _cham_xy, win_y - _cham_xy, case_h])
                cube([ACT_W + 2*_cham_xy, ACT_D + 2*_cham_xy, 0.01]);
        }

        // FPC cable slot — quarter-cylinder swept volume of cable arc from horizontal to vertical.
        // Arc center at (Y=DISP_D, Z=WALL−FPC_BEND_R); first-quadrant slice (Y≥DISP_D, Z≥arc_center_z).
        // Creates opening through backplate floor and clears Y+ wall material for bend.
        translate([_fpc_x1, BEZEL_Y + DISP_D, WALL - FPC_BEND_R])
            intersection() {
                rotate([0, 90, 0])
                    cylinder(r=_fpc_ro, h=_fpc_xw, $fn=32);
                cube([_fpc_xw, _fpc_ro + 1, _fpc_ro + 1]);
            }
    }

}

color("#004B49")
    intersection() {
        epd_case();
        cube([case_w + 1, case_d + 1,
              ($preview && CLIP_Z > 0) ? max(0.01, case_h - CLIP_Z) : case_h + 1]);
    }

// Display mockup — seated at case origin; EXPLODE pulls it toward Y-
if ($preview && SHOW_DISP)
    translate([WALL + TOL, BEZEL_Y - EXPLODE, WALL])
        GDEY0583T81(fpc_bend_start=0, fpc_bend_r=FPC_BEND_R, fpc_post_clip=2);