Little box for temp sensor

gistfile1.scad

// Uniform Enclosure for DFR1075, 18650 Battery, and Temp Sensor
// Fasteners: M3 Socket Head Cap Screws + M3 Heat-Set Inserts

wall = 2.5;
tolerance = 0.2; 

// --- Exterior Dimensions ---
outer_l = 96.0;
outer_w = 56.0;
outer_h = 28.0;

// --- Internal Dimensions ---
int_l = outer_l - wall*2; // 91mm
int_w = outer_w - wall*2; // 51mm
int_h = outer_h - wall;   // 25.5mm

// --- Zones ---
batt_zone_w = 22.0;
pcb_zone_w = int_w - batt_zone_w; 
pcb_zone_l = 64.0; 

// --- Hardware ---
post_w = 8.0;
insert_r = 2.0;     // 4.0mm hole for standard M3 short heat-set insert
insert_d = 6.0;     // Depth of the insert hole
screw_pass_r = 1.6; // 3.2mm clearance for M3 shaft
screw_head_r = 3.0; // 6.0mm clearance for M3 socket head
screw_head_h = 3.0; // Depth of counterbore

module box_base() {
    difference() {
        // Main solid body
        cube([outer_l, outer_w, outer_h]);
        
        // Hollow out the main internal cavity
        translate([wall, wall, wall])
            cube([int_l, int_w, int_h + 1]);
            
        // USB-C Port Cutout (Left Wall)
        // Oversized to 12x8mm to accommodate various cable boots
        translate([-1, wall + batt_zone_w + (pcb_zone_w/2) - 6, wall])
            cube([wall + 2, 12, 8]);
            
        // Sensor Ventilation (Right Wall)
        for(y = [wall + batt_zone_w + 4 : 3 : outer_w - wall - 4]) {
            translate([outer_l - wall - 1, y, wall + 2])
                cube([wall + 2, 1.2, int_h - 4]);
        }
        
        // Sensor Ventilation (Top Wall)
        for(x = [wall + pcb_zone_l + 6 : 3 : outer_l - wall - 4]) {
            translate([x, outer_w - wall - 1, wall + 2])
                cube([1.2, wall + 2, int_h - 4]);
        }
    }
    
    // Internal Thermal Partitions (Fully encloses sensor)
    translate([wall + pcb_zone_l, wall + batt_zone_w, wall]) {
        difference() {
            union() {
                // Wall separating PCB and Sensor
                cube([2, pcb_zone_w, int_h]);
                // Wall separating Battery and Sensor
                cube([int_l - pcb_zone_l, 2, int_h]);
            }
            // Wire pass-through port at the bottom of the PCB wall
            translate([-1, 4, 0])
                cube([4, 5, 4]);
        }
    }
        
    // Battery Cradle (keeps the round cell centered)
    translate([wall + int_l/2, wall + batt_zone_w/2, wall])
        battery_cradle();

    // M3 Corner Posts
    translate([wall, wall, wall]) corner_post();
    translate([outer_l - wall - post_w, wall, wall]) corner_post();
    translate([wall, outer_w - wall - post_w, wall]) corner_post();
    translate([outer_l - wall - post_w, outer_w - wall - post_w, wall]) corner_post();
}

module corner_post() {
    difference() {
        cube([post_w, post_w, int_h]);
        // Heat-set insert pilot hole
        translate([post_w/2, post_w/2, int_h - insert_d])
            cylinder(r=insert_r, h=insert_d + 1, $fn=32);
    }
}

module battery_cradle() {
    cradle_l = 72;
    cradle_w = 18;
    difference() {
        translate([-cradle_l/2, -cradle_w/2, 0])
            cube([cradle_l, cradle_w, 3]);
            
        translate([0, 0, 9 + 1]) rotate([0, 90, 0])
            cylinder(h=cradle_l+2, r=9.5, center=true, $fn=64);
    }
}

module box_lid() {
    lid_thickness = wall;
    difference() {
        union() {
            // Main lid body
            cube([outer_l, outer_w, lid_thickness]);
            
            // Registration Lip (keeps lid seated)
            translate([wall + tolerance, wall + tolerance, lid_thickness])
                difference() {
                    cube([int_l - tolerance*2, int_w - tolerance*2, 1.5]);
                    
                    // Clear the corners for the posts
                    translate([-1, -1, -1]) cube([post_w + 1, post_w + 1, 4]);
                    translate([int_l - post_w - tolerance*2, -1, -1]) cube([post_w + 1, post_w + 1, 4]);
                    translate([-1, int_w - post_w - tolerance*2, -1]) cube([post_w + 1, post_w + 1, 4]);
                    translate([int_l - post_w - tolerance*2, int_w - post_w - tolerance*2, -1]) cube([post_w + 1, post_w + 1, 4]);
                    
                    // Clear the thermal partition walls
                    translate([pcb_zone_l - tolerance, batt_zone_w - tolerance, -1]) {
                        // PCB/Sensor wall clearance
                        cube([2 + tolerance*2, pcb_zone_w + tolerance*2, 4]);
                        // Battery/Sensor wall clearance
                        cube([int_l - pcb_zone_l + tolerance*2, 2 + tolerance*2, 4]);
                    }
                }
        }
        
        // Counterbored M3 Screw Holes
        post_centers = [
            [wall + post_w/2, wall + post_w/2],
            [outer_l - wall - post_w/2, wall + post_w/2],
            [wall + post_w/2, outer_w - wall - post_w/2],
            [outer_l - wall - post_w/2, outer_w - wall - post_w/2]
        ];
        
        for (p = post_centers) {
            translate([p[0], p[1], -1]) {
                // Shaft clearance
                cylinder(r=screw_pass_r, h=lid_thickness + 4, $fn=32);
                // Head counterbore
                translate([0, 0, lid_thickness - screw_head_h + 1])
                    cylinder(r=screw_head_r, h=screw_head_h + 1, $fn=32);
            }
        }
    }
}

// --- Render Targets ---
box_base();

// Translate lid out of the way for visualization
translate([0, outer_w + wall*3, 0]) 
    box_lid();