keyboard.jscad

// title      : keyboard
// author     : Joost Nieuwenhuijse
// license    : MIT License
// description: a lamp shade
// file       : lamp-shade.jscad

function main (params) {
  CSG.defaultResolution2D = (params.quality === 'DRAFT') ? 8 : 32;

  var bottomradius = params.bottomdiameter / 2;
  var topradius = params.topdiameter / 2;
  var height = params.height;
  var numfaces = params.numfaces;
  var thickness = params.thickness;
  var topholeradius = params.topholediameter / 2;
  var cutterRadius = params.cutterdiameter / 2;

  var solid = CSG.cube({radius: [1000, 1000, height / 2]});

  var plane = CSG.Plane.fromPoints([bottomradius, 0, -height / 2], [bottomradius, 10, -height / 2], [topradius, 0, height / 2]);
  for (var i = 0; i < numfaces; i++) {
    solid = solid.cutByPlane(plane.rotateZ(i * 360 / numfaces));
  }

  var plates = solidToOuterShellPlates(solid, thickness);
  plates = removePlateWithNormal(plates, [0, 0, -1]);
  plates = removePlateWithNormal(plates, [0, 0, 1]);

  for (var j = 1; j < numfaces; j++) {
    plates[j] = plates[0].rotateZ(j * 360 / numfaces);
  }

  var topplate = getStockPlate(1000, 1000, thickness)
    .subtract(CSG.cylinder({start: [0, 0, -thickness], end: [0, 0, thickness], radius: topholeradius}))
    .translate([0, 0, height / 2 - thickness / 2 - 10]);
  topplate = topplate.intersect(solid);
  topplate = fixPlate(topplate, thickness);

  var fingerjointoptions = {
    margin: 0, cutterRadius: cutterRadius, fingerWidth: 25
  };
  plates = fingerJoint(plates, fingerjointoptions);
  plates = fingerJointAdd(plates, topplate, fingerjointoptions);

  if (params.type === 'TOPPLATE') {
    return plateCSGToCAG(plates[numfaces]);
  } else {
    var plate2d = plateCSGToCAG(plates[0]);
    plate2d = addRandomHoles(plate2d);
    if (params.type === 'SIDEPLATE') {
      return plate2d;
    } else {
      for (var k = 0; k < numfaces; k++) {
        var plate3d = plateCAGToCSG(plate2d, plates[k].properties.platebasis, thickness);
        plates[k] = plate3d;
      }
      var result = new CSG().union(plates);
      result = result.rotateX(90);
      return result;
    }
  }
}

function addRandomHoles (plate) {
  var distancefromedge = 8;
  var distancebetweenholes = 10;
  var mindiameter = 10;
  var maxdiameter = 25;
  // maskarea: the 'forbidden' area for holes:
  var maskarea = plate.contract(distancefromedge, 4);
  var bounds = maskarea.getBounds();
  maskarea = maskarea.flipped();
  var holes = [];
  var existingholecenters = [];
  var existingholeradii = [];
  for (var i = 0; i < 10; i++) {
    for (var tryindex = 0; tryindex < 10; tryindex++) {
      var holeradius = (mindiameter + Math.random() * (maxdiameter - mindiameter)) / 2;
      var x = bounds[0].x + holeradius + (bounds[1].x - bounds[0].x - holeradius * 2) * Math.random();
      var y = bounds[0].y + holeradius + (bounds[1].y - bounds[0].y - holeradius * 2) * Math.random();
      var holecenter = new CSG.Vector2D(x, y);
      var valid = true;
      // check if the hole is too close to one of the existing holes:
      var numexistingholes = existingholecenters.length;
      for (var i2 = 0; i2 < numexistingholes; i2++) {
        var d = holecenter.minus(existingholecenters[i2]).length();
        if (d < holeradius + existingholeradii[i2] + distancebetweenholes) {
          valid = false;
          break;
        }
      }
      if (valid) {
        // check if the hole is not too close to the edges:
        var hole = CAG.circle({radius: holeradius, center: holecenter});
        var testarea = maskarea.intersect(hole);
        if (testarea.sides.length !== 0) valid = false;
        if (valid) {
          existingholeradii.push(holeradius);
          existingholecenters.push(holecenter);
          holes.push(hole);
          break;
        }
      }
    }
  }
  return plate.subtract(holes);
}

function plateCSGToCAG (plate) {
  if (!('platebasis' in plate.properties)) {
    throw new Error('Plates should be created using getStockPlate()');
  }
  var plate2d = plate.projectToOrthoNormalBasis(plate.properties.platebasis);
  return plate2d;
}

function plateCAGToCSG (plate2d, platebasis, thickness) {
  var basisinversematrix = platebasis.getInverseProjectionMatrix();
  var plateReprojected = plate2d.extrude({offset: [0, 0, thickness]}).translate([0, 0, -thickness / 2]);
  plateReprojected = plateReprojected.transform(basisinversematrix);
  plateReprojected.properties.platebasis = platebasis;
  return plateReprojected;
}

function fixPlate (plate, thickness) {
  return plateCAGToCSG(plateCSGToCAG(plate), plate.properties.platebasis, thickness);
}

function removePlateWithNormal (plates, normalvector) {
  normalvector = new CSG.Vector3D(normalvector);
  var result = [];
  plates.map(function (plate) {
    if (!('platebasis' in plate.properties)) {
      throw new Error('Plates should be created using getStockPlate()');
    }
    if (plate.properties.platebasis.plane.normal.dot(normalvector) < 0.9999) {
      result.push(plate);
    }
  });
  return result;
}

function getStockPlate (width, height, thickness) {
  var result = CSG.cube({radius: [width / 2, height / 2, thickness / 2]});
  result.properties.platebasis = CSG.OrthoNormalBasis.Z0Plane();
  return result;
}

function fingerJointAdd (plates, newplate, options) {
  var result = plates.slice(0);
  var numplates = plates.length;
  for (var plateindex1 = 0; plateindex1 < numplates; plateindex1++) {
    var joined = fingerJointTwo(result[plateindex1], newplate, options);
    result[plateindex1] = joined[0];
    newplate = joined[1];
  }
  result.push(newplate);
  return result;
}

// Finger joint between multiple plates:
function fingerJoint (plates, options) {
  var result = plates.slice(0);
  var numplates = plates.length;
  var maxdelta = Math.floor(numplates / 2);
  for (var delta = 1; delta <= maxdelta; delta++) {
    for (var plateindex1 = 0; plateindex1 < numplates; plateindex1++) {
      var plateindex2 = plateindex1 + delta;
      if (plateindex2 >= numplates) plateindex2 -= numplates;

      var joined = fingerJointTwo(result[plateindex1], result[plateindex2], options);
      result[plateindex1] = joined[0];
      result[plateindex2] = joined[1];
      if (delta * 2 >= numplates) {
        // numplates is even
        if (plateindex1 * 2 >= numplates) {
          // and we've done the first half: we're done
          break;
        }
      }
    }
  }
  return result;
}

function fingerJointTwo (plate1, plate2, options) {
  if (!options) options = {};
  if (!('platebasis' in plate1.properties)) {
    throw new Error('Plates should be created using getStockPlate()');
  }
  if (!('platebasis' in plate2.properties)) {
    throw new Error('Plates should be created using getStockPlate()');
  }
  // get the intersection solid of the 2 plates:
  var intersection = plate1.intersect(plate2);
  if (intersection.polygons.length === 0) {
    // plates do not intersect. Return unmodified:
    return [plate1, plate2];
  } else {
    var plane1 = plate1.properties.platebasis.plane;
    var plane2 = plate2.properties.platebasis.plane;
    // get the intersection line of the 2 center planes:
    var jointline = plane1.intersectWithPlane(plane2);
    // Now we need to find the two endpoints on jointline (the points at the edges of intersection):
    // construct a plane perpendicular to jointline:
    plane1 = CSG.Plane.fromNormalAndPoint(jointline.direction, jointline.point);
    // make the plane into an orthonormal basis:
    var basis1 = new CSG.OrthoNormalBasis(plane1);
    // get the projection matrix for the orthobasis:
    var matrix = basis1.getProjectionMatrix();
    // now transform the intersection solid:
    var intersectionTransformed = intersection.transform(matrix);
    var bounds = intersectionTransformed.getBounds();
    // now we know the two edge points. The joint line runs from jointlineOrigin, in the
    // direction jointlineDirection and has a length jointlineLength (jointlineLength >= 0)
    var jointlineOrigin = jointline.point.plus(jointline.direction.times(bounds[0].z));
    var jointlineDirection = jointline.direction;
    var jointlineLength = bounds[1].z - bounds[0].z;

    var fingerwidth = options.fingerWidth || (jointlineLength / 4);
    var numfingers = Math.round(jointlineLength / fingerwidth);
    if (numfingers < 2) numfingers = 2;
    fingerwidth = jointlineLength / numfingers;

    var margin = options.margin || 0;
    var cutterRadius = options.cutterRadius || 0;
    var results = [];
    for (var plateindex = 0; plateindex < 2; plateindex++) {
      var thisplate = (plateindex === 1) ? plate2 : plate1;
      // var otherplate = (plateindex === 1) ? plate1 : plate2;
      // create a new orthonormal basis for this plate, such that the joint line runs in the positive x direction:
      var platebasis = new CSG.OrthoNormalBasis(thisplate.properties.platebasis.plane, jointlineDirection);
      // get the 2d shape of our plate:
      var plate2d = thisplate.projectToOrthoNormalBasis(platebasis);
      var jointlineOrigin2d = platebasis.to2D(jointlineOrigin);
      matrix = platebasis.getProjectionMatrix();
      intersectionTransformed = intersection.transform(matrix);
      bounds = intersectionTransformed.getBounds();
      var maxz = bounds[1].z;
      var minz = bounds[0].z;
      var maxy = bounds[1].y + margin / 2;
      var miny = bounds[0].y - margin / 2;

      var cutouts2d = [];
      for (var fingerindex = 0; fingerindex < numfingers; fingerindex++) {
        if ((plateindex === 0) && ((fingerindex & 1) === 0)) continue;
        if ((plateindex === 1) && ((fingerindex & 1) !== 0)) continue;
        var minx = jointlineOrigin2d.x + fingerindex * fingerwidth - margin / 2;
        var maxx = minx + fingerwidth + margin;
        var cutout = createRectCutoutWithCutterRadius(minx, miny, maxx, maxy, cutterRadius, plate2d);
        cutouts2d.push(cutout);
      }
      var cutout2d = new CAG().union(cutouts2d);
      var cutout3d = cutout2d.extrude({offset: [0, 0, maxz - minz]}).translate([0, 0, minz]);
      cutout3d = cutout3d.transform(platebasis.getInverseProjectionMatrix());
      var thisplateModified = thisplate.subtract(cutout3d);
      results[plateindex] = thisplateModified;
    }
    return results;
  }
}

// Create a rectangular cutout in 2D
// minx, miny, maxx, maxy: boundaries of the rectangle
// cutterRadius: if > 0, add extra cutting margin at the corners of the rectangle
// plate2d is the 2d shape from which the cutout will be subtracted
// it is tested at the corners of the cutout rectangle, to see if do need to add the extra margin at that corner

function createRectCutoutWithCutterRadius (minx, miny, maxx, maxy, cutterRadius, plate2d) {
  var deltax = maxx - minx;
  var deltay = maxy - miny;
  var cutout = CAG.rectangle({radius: [(maxx - minx) / 2, (maxy - miny) / 2], center: [(maxx + minx) / 2, (maxy + miny) / 2]});
  var cornercutouts = [];
  if (cutterRadius > 0) {
    var extracutout = cutterRadius * 0.2;
    var hypcutterradius = cutterRadius / Math.sqrt(2.0);
    var halfcutterradius = 0.5 * cutterRadius;
    var dcx, dcy;
    if (deltax > 3 * deltay) {
      dcx = cutterRadius + extracutout / 2;
      dcy = extracutout / 2;
    } else if (deltay > 3 * deltax) {
      dcx = extracutout / 2;
      dcy = cutterRadius + extracutout / 2;
    } else {
      dcx = hypcutterradius - extracutout / 2;
      dcy = hypcutterradius - extracutout / 2;
    }
    for (var corner = 0; corner < 4; corner++) {
      var cutoutcenterx = (corner & 2) ? (maxx - dcx) : (minx + dcx);
      var cutoutcentery = (corner & 1) ? (maxy - dcy) : (miny + dcy);
      var cornercutout = CAG.rectangle({radius: [cutterRadius + extracutout / 2, cutterRadius + extracutout / 2], center: [cutoutcenterx, cutoutcentery]});
      var testrectacenterx = (corner & 2) ? (maxx - halfcutterradius) : (minx + halfcutterradius);
      var testrectbcenterx = (corner & 2) ? (maxx + halfcutterradius) : (minx - halfcutterradius);
      var testrectacentery = (corner & 1) ? (maxy + halfcutterradius) : (miny - halfcutterradius);
      var testrectbcentery = (corner & 1) ? (maxy - halfcutterradius) : (miny + halfcutterradius);
      var testrecta = CAG.rectangle({radius: [halfcutterradius, halfcutterradius], center: [testrectacenterx, testrectacentery]});
      var testrectb = CAG.rectangle({radius: [halfcutterradius, halfcutterradius], center: [testrectbcenterx, testrectbcentery]});
      if ((plate2d.intersect(testrecta).sides.length > 0) && (plate2d.intersect(testrectb).sides.length > 0)) {
        cornercutouts.push(cornercutout);
      }
    }
  }
  if (cornercutouts.length > 0) {
    cutout = cutout.union(cornercutouts);
  }
  return cutout;
}

function solidToOuterShellPlates (csg, thickness) {
  csg = csg.canonicalized();
  var bounds = csg.getBounds();
  var csgcenter = bounds[1].plus(bounds[0]).times(0.5);
  var csgradius = bounds[1].minus(bounds[0]).length();
  var plane2polygons = {};
  csg.polygons.map(function (polygon) {
    var planetag = polygon.plane.getTag();
    if (!(planetag in plane2polygons)) {
      plane2polygons[planetag] = [];
    }
    plane2polygons[planetag].push(polygon);
  });
  var plates = [];
  for (var planetag in plane2polygons) {
    var polygons = plane2polygons[planetag];
    var plane = polygons[0].plane;
    var shellcenterplane = new CSG.Plane(plane.normal, plane.w - thickness / 2);
    var basis = new CSG.OrthoNormalBasis(shellcenterplane);
    var inversebasisprojection = basis.getInverseProjectionMatrix();
    var csgcenterProjected = basis.to2D(csgcenter);
    var plate = getStockPlate(csgradius, csgradius, thickness).translate([csgcenterProjected.x, csgcenterProjected.y, 0]);
    plate = plate.transform(inversebasisprojection);
    plate = plate.intersect(csg);
    plates.push(plate);
  }
  return plates;
}

function getParameterDefinitions () {
  return [
    {name: 'topdiameter', type: 'float', initial: 160, caption: 'Top diameter:'},
    {name: 'bottomdiameter', type: 'float', initial: 300, caption: 'Bottom diameter:'},
    {name: 'height', type: 'float', initial: 170, caption: 'Height:'},
    {name: 'numfaces', type: 'int', initial: 5, caption: 'Number of faces:'},
    {name: 'thickness', type: 'float', initial: 4, caption: 'Thickness of stock material:'},
    {name: 'topholediameter', type: 'float', initial: 42, caption: 'Diameter of top hole:'},
    {name: 'cutterdiameter', type: 'float', initial: 3.2, step: 0.1, caption: 'Diameter of CNC cutter / laser beam:'},
    {
      name: 'type',
      type: 'choice',
      values: ['ASSEMBLED', 'TOPPLATE', 'SIDEPLATE'], // these are the values that will be supplied to your script
      captions: ['Assembled', 'Top plate (DXF output)', 'Side plate (DXF output)'], // optional, these values are shown in the listbox
      // if omitted, the items in the 'values' array are used
      caption: 'Show:', // optional, displayed left of the input field
      initial: 'ASSEMBLED' // optional, default selected value
      // if omitted, the first item is selected by default
    },
    {
      name: 'quality',
      type: 'choice',
      values: ['DRAFT', 'HIGH'], // these are the values that will be supplied to your script
      captions: ['Draft', 'High'], // optional, these values are shown in the listbox
      // if omitted, the items in the 'values' array are used
      caption: 'Quality:', // optional, displayed left of the input field
      initial: 'DRAFT' // optional, default selected value
      // if omitted, the first item is selected by default
    }
  ];
}