epaper_nametag/cable_cap.scad

// Waveshare 2.13" e-Paper HAT (B) — ESP32 Nametag Case
// Display slides in from X+; FPC cable exits freely out the open X+ side

// --- 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  (closed/backstop side)
//   X+: portrait FPC border  ≈ 8.70 mm  (open/entry side)
//   Y±: symmetric            ≈ 2.75 mm  each side
ACT_X_OFFSET = 1.95;
ACT_Y_OFFSET = 2.75;

// --- FPC Cable (exits X+ side) ---
FPC_W   = 12.5;
FPC_T   = 0.3;
FPC_LEN = 20.0;   // visualization length of hanging tail

// --- FPC Return Pocket ---
FPC_FLOOR_DROP  = 0.75;  // extra depth below display cavity floor
FPC_POCKET_LEN  = 20.0;  // how far in from X+ face the pocket extends
FPC_POCKET_PAD  = 2.0;   // padding on each side of FPC cable width

// --- Case Parameters ---
WALL       = 3.0;   // must exceed MAG_LIP_H (2.0) to keep pocket floor
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;
CLIP_Z     = 0;     // preview: mm to remove from Z+ (0 = full model)
CLIP_Y     = 6;     // preview: mm to remove from Y+ (0 = full model)
SHOW_DISP  = true;
SCREEN_EXPLODE    = 0;     // mm to pull display toward X+ in preview

// --- Magnetic Strip Locating Lip (rear 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;            // lip height protruding from rear face
MAG_LIP_WALL = 1.0;            // lip wall thickness
MAG_TOL      = 0.2;            // per-side clearance for strip fit

// --- Derived Dimensions ---
cav_w  = DISP_W + TOL * 2;
cav_d  = DISP_D + TOL * 2;
case_w = WALL + cav_w;          // no X+ wall; open for display entry
case_h = WALL + DISP_T + LIP;
case_d = WALL * 2 + cav_d;

_cham_xy = CHAM * tan(CHAM_ANGLE);

win_x = WALL + TOL + ACT_X_OFFSET;
win_y = WALL + TOL + ACT_Y_OFFSET;

// FPC return pocket geometry (X+ face)
fpc_pkt_y  = WALL + TOL + (DISP_D - FPC_W) / 2 - FPC_POCKET_PAD;
fpc_pkt_yw = FPC_W + 2 * FPC_POCKET_PAD;

// Magnetic strip recess geometry (centered on back face)
_lip_il = MAG_L + 2 * MAG_TOL;
_lip_iw = MAG_W + 2 * MAG_TOL;
_lip_x  = case_w / 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() {
    difference() {
        rounded_box(case_w, case_d, case_h, CORNER_R);

        // Display cavity — extends 0.01 mm past X+ face to leave that side open
        translate([WALL, WALL, WALL])
            cube([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]);
        }

        // FPC return pocket — drops floor of display cavity near X+ face
        translate([case_w - FPC_POCKET_LEN, fpc_pkt_y, WALL - FPC_FLOOR_DROP - 0.01])
            cube([FPC_POCKET_LEN + 0.02, fpc_pkt_yw, DISP_T + TOL + FPC_FLOOR_DROP + 0.01]);

        // Magnetic strip recess in back face
        translate([_lip_x, _lip_y, -0.01])
            cube([_lip_il, _lip_iw, MAG_LIP_H + 0.01]);
    }
}

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

if ($preview && SHOW_DISP)
    translate([WALL + TOL + SCREEN_EXPLODE, WALL + TOL, WALL])
        EPD213B();