Bus Pirate v3.6 case, created in OpenSCAD

README.md

Case for Bus Pirate v3.6 (Dangerous Prototypes/Seeedstudio version)

This is a case for the Bus Pirate v3.6 from Dangerous Prototypes as listed on Thingiverse to be printed on a 3D printer.

In order to compile this file to an STL you'll need OpenSCAD and also the file oshw.scad which you can find here on Thingiverse.

case_bp_3.6.v1.0.scad

include <oshw.scad>

fudge_factor=0.75;

board_length=60.1 + fudge_factor;
board_width=37.1 + fudge_factor;
board_thickness=1.65;

board_corner_radius=3.3 + fudge_factor/2;

board_clearance_top=0;
board_clearance_bottom=2;
clearance_top=2;

usb_width=8.6;
usb_height=4.6;

cutout_header_width=20.3 + 1;
cutout_header_length=8.9 + 1;
header_distance_board_edge=8.5;

cutout_icsp_width=4;
cutout_icsp_length=14.6;
icsp_distance_board_edge=3.6;

cutout_leds_length=35;
cutout_leds_width=3;
leds_distance_board_edge=2.5;

wall_strength=1.2;
lip_strength=1;

corner_radius=1.5;

$fn=32;

module rounded_box(w, l, h, r) {
  inner_length = l - 2 * r;
  inner_width = w - 2 * r;
	
	hull() {
		translate([-inner_width / 2, -inner_length/2, 0]) cylinder(r=r, h=h);
		translate([inner_width / 2, -inner_length/2, 0]) cylinder(r=r, h=h);
		translate([inner_width / 2, inner_length/2, 0]) cylinder(r=r, h=h);
		translate([-inner_width / 2, inner_length/2, 0]) cylinder(r=r, h=h);
	}
}

module case_bottom() {
	case_bottom_width=board_width + 2 * wall_strength;
	case_bottom_length=board_length + 2 * wall_strength;
	case_bottom_height=board_thickness + board_clearance_bottom + usb_height/2 + board_clearance_top + wall_strength;

	difference() {
		rounded_box(case_bottom_width, case_bottom_length, case_bottom_height, board_corner_radius + wall_strength);
		translate([0, 0, wall_strength + board_clearance_bottom]) 
			rounded_box(board_width, board_length, case_bottom_height, board_corner_radius); // resting area
		translate([0, 0, wall_strength]) 
			rounded_box(board_width - 2 * lip_strength, board_length - 2 * lip_strength, case_bottom_height, board_corner_radius - lip_strength); // board cutout
		
		// usb cutout
		translate([0, board_length * 0.5, usb_height/2 + wall_strength + board_clearance_bottom + board_thickness]) cube(size=[usb_width, 20, usb_height], center=true);
		
		// locks ICSP side
		hull() {
			translate([-board_width/2, -board_length/4 - 5, case_bottom_height - lip_strength / 2]) sphere(r=0.4, center=true);
			translate([-board_width/2, -board_length/4 + 5, case_bottom_height - lip_strength / 2]) sphere(r=0.4, center=true);
		}
		hull() {
			translate([-board_width/2, board_length/4 - 5, case_bottom_height - lip_strength / 2]) sphere(r=0.4, center=true);
			translate([-board_width/2, board_length/4 + 5, case_bottom_height - lip_strength / 2]) sphere(r=0.4, center=true);
		}

		// lock LED side
		hull() {
			translate([board_width/2, -board_length/4 - 5, case_bottom_height - lip_strength / 2]) sphere(r=0.3, center=true);
			translate([board_width/2, board_length/4 + 5, case_bottom_height - lip_strength / 2]) sphere(r=0.3, center=true);
		}
	}

}

module case_top() {
	usb_height_remainder = usb_height/2;

	// bottom part
	case_top_width=board_width + 2 * wall_strength;
	case_top_length=board_length + 2 * wall_strength;
	case_top_height=usb_height_remainder + wall_strength + clearance_top;
	
	// top/lip part
	case_top_width_lip=case_top_width - 2 * lip_strength - 0.5;
	case_top_length_lip=case_top_length - 2 * lip_strength - 0.5;
	case_top_height_lip=case_top_height + lip_strength;
	
	union() {
		difference() {
			union() {
				rounded_box(case_top_width, case_top_length, case_top_height, board_corner_radius + wall_strength);
				rounded_box(case_top_width_lip, case_top_length_lip, case_top_height_lip, board_corner_radius);
			}
			translate([0,0,wall_strength]) 
				rounded_box(case_top_width - 2 * wall_strength - 2 * lip_strength, case_top_length - 2 * wall_strength - 2 * lip_strength, case_top_height, board_corner_radius - lip_strength);
			
			// usb cutout
			translate([0, board_length/2, wall_strength + clearance_top + usb_height_remainder]) cube(size=[usb_width, 20, usb_height], center=true);
			
			// header cutout
			translate([0,-board_length/2 + header_distance_board_edge,0])
				cube(size=[cutout_header_width, cutout_header_length, 20], center=true);
			
			// ICSP cutout
			translate([board_width/2 - icsp_distance_board_edge, 0, -10])
				rounded_box(cutout_icsp_width, cutout_icsp_length, 20, cutout_icsp_width/4);
				//cube(size=[cutout_icsp_width, cutout_icsp_length, 20], center=true);
			
			// LED cutout
			translate([-board_width/2 + leds_distance_board_edge, 0, -10])
				rounded_box(cutout_leds_width, cutout_leds_length, 20, cutout_leds_width/2);

			// oshw logo
			translate([0,0,-0.4]) rotate([0,0,90]) linear_extrude(height=1)
				oshw_logo_2d(25);

		}
		
		// lock LED side
		hull() {
			translate([case_top_width/2 - wall_strength, -board_length/4 - 5, case_top_height_lip - lip_strength / 2]) sphere(r=0.2, center=true);
			translate([case_top_width/2 - wall_strength, -board_length/4 + 5, case_top_height_lip - lip_strength / 2]) sphere(r=0.2, center=true);
		}
		hull() {
			translate([case_top_width/2 - wall_strength, board_length/4 - 5, case_top_height_lip - lip_strength / 2]) sphere(r=0.2, center=true);
			translate([case_top_width/2 - wall_strength, board_length/4 + 5, case_top_height_lip - lip_strength / 2]) sphere(r=0.2, center=true);
		}

		// locks ICSP side
		hull() {
			translate([-case_top_width/2 + wall_strength, -board_length/4 - 5, case_top_height_lip - lip_strength / 2]) sphere(r=0.2, center=true);
			translate([-case_top_width/2 + wall_strength, board_length/4 + 5, case_top_height_lip - lip_strength / 2]) sphere(r=0.2, center=true);
		}

	}
}

case_bottom();
translate([board_width + 2 * wall_strength + 5, 0, 0]) case_top();