// Waveshare 2.13" e-Paper HAT (B) — ESP32 Nametag Case // Display slides in from X−; FPC routes through internal 180° bend guide at X+ // --- Display Dimensions (landscape: portrait rotated 90°) --- DISP_W = 59.20; // overall width (X) — portrait height DISP_D = 29.20; // overall depth (Y) — portrait width DISP_T = 1.0; // thickness (Z) // --- Active (Visible) Area --- ACT_W = 48.55; // active area width (X) — portrait AA height ACT_D = 23.71; // active area depth (Y) — portrait AA width // Border offsets from display edge to active area: // X-: portrait top border ≈ 1.95 mm (open/entry side) // X+: portrait FPC border ≈ 8.70 mm (closed/backstop; FPC exits here) // Y±: symmetric ≈ 2.75 mm each side ACT_X_OFFSET = 1.95; ACT_Y_OFFSET = 2.75; // --- FPC Cable (exits X+ side of display) --- FPC_W = 12.5; FPC_T = 0.3; FPC_LEN = 20.0; // visualization length of hanging tail // --- FPC Bend Guide --- BEND_R = 2.0; // inner bend radius (mm) BEND_WALL = 1.5; // wall thickness around channel (mm) // --- FPC Excess-Cable Pocket (under display floor) --- FPC_POCKET_D = 0.75; // depth below display floor (Z), slip-fit with assembly clearance FPC_POCKET_L = 20.0; // length running toward X− from the X+ cavity wall // --- Resin Drain Holes (Z− face, under bend guide arc bottom) --- DRAIN_HOLES = true; // enable drain holes for SLA printing DRAIN_D = 3.0; // hole diameter (mm) DRAIN_MARGIN = 1.0; // clearance from FPC cable corner to hole edge (mm) // --- Case Parameters --- WALL = 4.2; // = BEND_WALL + 2*BEND_R − DISP_T − TOL: keeps exactly BEND_WALL below channel LIP = 1.5; // front bezel lip thickness (Z) TOL = 0.3; // per-side display clearance CHAM = 1.0; CHAM_ANGLE = 60; CORNER_R = 2.5; X_PAD = 0; // extra bezel thickness added at X− (entry) end // --- Magnetic Strip Pocket (back face) --- MAG_L = 1.772 * 25.4; // strip length ≈ 45.01 mm MAG_W = 0.512 * 25.4; // strip width ≈ 13.00 mm MAG_LIP_H = 2.0; // pocket depth MAG_TOL = 0.2; // per-side clearance // --- Preview Controls --- SHOW_DISP = false; SCREEN_EXPLODE = 0; // mm to pull display toward X− in preview SLICE_Z = 0; // show only below this Z for cross-section view (0 = off) SLICE_Y = 25; // show only below this Y for cross-section view (0 = off) // --- Derived Dimensions --- cav_w = DISP_W + TOL * 2; cav_d = DISP_D + TOL * 2; case_w = WALL + cav_w; // WALL on X+; guide flat face at x=case_w case_h = WALL + DISP_T + LIP; case_d = WALL * 2 + cav_d; _guide_or = BEND_R + BEND_WALL; // guide depth; case extends this far past case_w _guide_cz = WALL + DISP_T + TOL - BEND_R; // guide center Z: aligns guide top with entry slot top _sweep_half = 112.5; // half of 225° sweep; arms exit at ±_sweep_half° _exit_x = case_w + BEND_R * cos(-_sweep_half); // X of bottom exit arm on inner radius _exit_z = _guide_cz + BEND_R * sin(-_sweep_half); // Z of bottom exit arm on inner radius _exit_span_x = abs(BEND_R * cos(_sweep_half)); // X span from arc tip back to guide center _cham_xy = CHAM * tan(CHAM_ANGLE); // Drain holes: punched from Z− face up to just inside the arc bottom // Y offset keeps hole edges DRAIN_MARGIN clear of FPC cable corners (at ±FPC_W/2 from center) _drain_depth = _guide_cz - BEND_R + 0.5; // 1.8 mm solid + 0.5 mm into arc _drain_y_off = FPC_W / 2 - DRAIN_D / 2 - DRAIN_MARGIN; // inset from cable corner win_x = X_PAD + TOL + ACT_X_OFFSET; win_y = WALL + TOL + ACT_Y_OFFSET; // Magnetic strip pocket centered on full case length (including guide extension and X_PAD) _lip_il = MAG_L + 2 * MAG_TOL; _lip_iw = MAG_W + 2 * MAG_TOL; _lip_x = (X_PAD + case_w + _guide_or) / 2 - _lip_il / 2; _lip_y = case_d / 2 - _lip_iw / 2; // ------------------------------------------------------------------- // Display mockup — approximate geometry for preview only // ------------------------------------------------------------------- module EPD213B() { color([0.82, 0.84, 0.80]) cube([DISP_W, DISP_D, DISP_T]); color("white") translate([ACT_X_OFFSET, ACT_Y_OFFSET, DISP_T]) cube([ACT_W, ACT_D, 0.02]); color([1.0, 0.85, 0.1]) translate([DISP_W, (DISP_D - FPC_W) / 2, (DISP_T - FPC_T) / 2]) cube([FPC_LEN, FPC_W, FPC_T]); } // ------------------------------------------------------------------- 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() { _slot_w = FPC_W + 1.0; // 0.5 mm per-side assembly clearance difference() { // Case body extended in X+ to enclose the bend guide, X_PAD extends X− end rounded_box(X_PAD + case_w + _guide_or, case_d, case_h, CORNER_R); // Display cavity — slot opens through X− face, extends full depth including X_PAD translate([-0.01, WALL, WALL]) cube([X_PAD + cav_w + 0.01, cav_d, DISP_T + TOL]); // Active area window + chamfered top edges 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]); } // Magnetic strip pocket in back face translate([_lip_x, _lip_y, -0.01]) cube([_lip_il, _lip_iw, MAG_LIP_H + 0.01]); // Combined cable channel — entry + return, interior walls removed // Top is flat at WALL+DISP_T+TOL; floor slopes up from guide exit to cavity wall hull() { translate([X_PAD + _exit_x - 0.01, case_d / 2 - _slot_w / 2, _exit_z]) cube([_exit_span_x + 0.01, _slot_w, WALL + DISP_T + TOL - _exit_z]); translate([X_PAD + cav_w - 0.01, case_d / 2 - _slot_w / 2, WALL - FPC_POCKET_D]) cube([0.02, _slot_w, DISP_T + TOL + FPC_POCKET_D]); } // FPC excess-cable pocket below display floor — cable coils here after the bend guide translate([X_PAD + cav_w - FPC_POCKET_L, case_d / 2 - _slot_w / 2, WALL - FPC_POCKET_D]) cube([FPC_POCKET_L + 0.01, _slot_w, FPC_POCKET_D + 0.01]); // Internal 225° bend guide channel translate([X_PAD + case_w, case_d / 2, _guide_cz]) rotate([-90, 0, 0]) translate([0, 0, -_slot_w / 2]) linear_extrude(_slot_w) intersection() { circle(r = BEND_R, $fn = 64); polygon(concat([[0, 0]], [for (a = [112.5 : -5 : -112.5]) [(BEND_R + 0.01) * cos(a), (BEND_R + 0.01) * sin(a)]])); } // Resin drain holes through Z− face at arc bottom // Symmetric pair inset from FPC cable corners by DRAIN_MARGIN so cable glides past if (DRAIN_HOLES) for (s = [-1, 1]) translate([X_PAD + case_w, case_d / 2 + s * _drain_y_off, -0.01]) cylinder(d = DRAIN_D, h = _drain_depth + 0.01, $fn = 32); } } // ------------------------------------------------------------------- // Render // ------------------------------------------------------------------- color("#004B49") intersection() { epd_case(); cube([X_PAD + case_w + _guide_or + 1, ($preview && SLICE_Y > 0) ? SLICE_Y : case_d + 1, ($preview && SLICE_Z > 0) ? SLICE_Z : case_h + 1]); } if ($preview && SHOW_DISP) translate([X_PAD + TOL - SCREEN_EXPLODE, WALL + TOL, WALL]) EPD213B();