257 lines
8.7 KiB
Go
257 lines
8.7 KiB
Go
package main
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import (
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"fmt"
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"math"
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"os"
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)
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func WriteSCAD(filename string, triangles [][3]Point) error {
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// Fallback/legacy mesh WriteSCAD
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f, err := os.Create(filename)
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if err != nil {
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return err
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}
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defer f.Close()
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fmt.Fprintf(f, "// Generated by pcb-to-stencil\npolyhedron(\n points=[\n")
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for i, t := range triangles {
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fmt.Fprintf(f, " [%f, %f, %f], [%f, %f, %f], [%f, %f, %f]", t[0].X, t[0].Y, t[0].Z, t[1].X, t[1].Y, t[1].Z, t[2].X, t[2].Y, t[2].Z)
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if i < len(triangles)-1 {
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fmt.Fprintf(f, ",\n")
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} else {
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fmt.Fprintf(f, "\n")
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}
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}
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fmt.Fprintf(f, " ],\n faces=[\n")
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for i := 0; i < len(triangles); i++ {
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idx := i * 3
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fmt.Fprintf(f, " [%d, %d, %d]", idx, idx+1, idx+2)
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if i < len(triangles)-1 {
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fmt.Fprintf(f, ",\n")
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} else {
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fmt.Fprintf(f, "\n")
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}
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}
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fmt.Fprintf(f, " ]\n);\n")
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return nil
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}
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// ExtractPolygonFromGerber traces the Edge.Cuts gerber to form a continuous 2D polygon
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func ExtractPolygonFromGerber(gf *GerberFile) [][2]float64 {
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var points [][2]float64
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curX, curY := 0.0, 0.0
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interpolationMode := "G01"
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for _, cmd := range gf.Commands {
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if cmd.Type == "G01" || cmd.Type == "G02" || cmd.Type == "G03" {
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interpolationMode = cmd.Type
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continue
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}
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prevX, prevY := curX, curY
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if cmd.X != nil {
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curX = *cmd.X
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}
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if cmd.Y != nil {
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curY = *cmd.Y
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}
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if cmd.Type == "DRAW" {
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if len(points) == 0 {
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points = append(points, [2]float64{prevX, prevY})
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}
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if interpolationMode == "G01" {
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points = append(points, [2]float64{curX, curY})
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} else {
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iVal, jVal := 0.0, 0.0
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if cmd.I != nil {
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iVal = *cmd.I
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}
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if cmd.J != nil {
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jVal = *cmd.J
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}
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centerX, centerY := prevX+iVal, prevY+jVal
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radius := math.Sqrt(iVal*iVal + jVal*jVal)
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startAngle := math.Atan2(prevY-centerY, prevX-centerX)
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endAngle := math.Atan2(curY-centerY, curX-centerX)
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if interpolationMode == "G03" {
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if endAngle <= startAngle {
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endAngle += 2 * math.Pi
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}
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} else {
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if startAngle <= endAngle {
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startAngle += 2 * math.Pi
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}
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}
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arcLen := math.Abs(endAngle-startAngle) * radius
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steps := int(arcLen * 10)
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if steps < 5 {
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steps = 5
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}
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for s := 1; s <= steps; s++ {
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t := float64(s) / float64(steps)
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a := startAngle + t*(endAngle-startAngle)
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ax, ay := centerX+radius*math.Cos(a), centerY+radius*math.Sin(a)
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points = append(points, [2]float64{ax, ay})
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}
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}
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}
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}
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return points
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}
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// WriteNativeSCAD generates native parametrically defined CSG OpenSCAD code
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func WriteNativeSCAD(filename string, isTray bool, outlineVertices [][2]float64, cfg EnclosureConfig, holes []DrillHole, cutouts []SideCutout, minBX, maxBX, boardCenterY float64) error {
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f, err := os.Create(filename)
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if err != nil {
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return err
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}
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defer f.Close()
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fmt.Fprintf(f, "// Generated by pcb-to-stencil (Native SCAD)\n")
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fmt.Fprintf(f, "$fn = 60;\n\n")
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// 1. Output the Board Polygon Module
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fmt.Fprintf(f, "module board_polygon() {\n polygon(points=[\n")
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for i, v := range outlineVertices {
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fmt.Fprintf(f, " [%f, %f]", v[0], v[1])
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if i < len(outlineVertices)-1 {
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fmt.Fprintf(f, ",\n")
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}
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}
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fmt.Fprintf(f, "\n ]);\n}\n\n")
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// Dimensions
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clearance := cfg.Clearance
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wt := cfg.WallThickness
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lidThick := wt
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snapHeight := 2.5
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trayFloor := 1.5
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pcbT := cfg.PCBThickness
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totalH := cfg.WallHeight + pcbT + trayFloor
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lipH := pcbT + 1.5
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// Create Peg and Socket helper
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fmt.Fprintf(f, "module mounting_pegs(isSocket) {\n")
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for _, h := range holes {
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if h.Type == DrillTypeMounting {
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r := (h.Diameter / 2.0) - 0.15
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if isTray {
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// We subtract sockets from the tray floor
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r = (h.Diameter / 2.0) + 0.1
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fmt.Fprintf(f, " translate([%f, %f, -1]) cylinder(r=%f, h=%f);\n", h.X, h.Y, r, trayFloor+2)
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} else {
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fmt.Fprintf(f, " translate([%f, %f, 0]) cylinder(r=%f, h=%f);\n", h.X, h.Y, r, totalH-lidThick)
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}
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}
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}
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fmt.Fprintf(f, "}\n\n")
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// Print Side Cutouts module
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fmt.Fprintf(f, "module side_cutouts() {\n")
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for _, c := range cutouts {
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// Cutouts are relative to board.
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x, y, z := 0.0, 0.0, c.Height/2+trayFloor+pcbT
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w, d, h := c.Width, 20.0, c.Height // d is deep enough to cut through walls
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if c.Side == 0 { // Top
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y = outlineVertices[0][1] + 10 // rough outside pos
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x = c.X
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fmt.Fprintf(f, " translate([%f, %f, %f]) cube([%f, %f, %f], center=true);\n", x, y, z, w, d, h)
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} else if c.Side == 1 { // Right
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x = maxBX
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y = c.Y
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fmt.Fprintf(f, " translate([%f, %f, %f]) cube([%f, %f, %f], center=true);\n", x, y, z, d, w, h)
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} else if c.Side == 2 { // Bottom
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y = outlineVertices[0][1] - 10
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x = c.X
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fmt.Fprintf(f, " translate([%f, %f, %f]) cube([%f, %f, %f], center=true);\n", x, y, z, w, d, h)
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} else if c.Side == 3 { // Left
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x = minBX
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y = c.Y
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fmt.Fprintf(f, " translate([%f, %f, %f]) cube([%f, %f, %f], center=true);\n", x, y, z, d, w, h)
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}
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}
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fmt.Fprintf(f, "}\n\n")
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// Print Pry Slots Module
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fmt.Fprintf(f, "module pry_slots() {\n")
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pryW := 8.0
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pryD := 1.5
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fmt.Fprintf(f, " translate([%f, %f, 0]) cube([%f, %f, %f], center=true);\n", minBX-clearance-wt+pryD/2, boardCenterY, pryD*2, pryW, snapHeight*3)
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fmt.Fprintf(f, " translate([%f, %f, 0]) cube([%f, %f, %f], center=true);\n", maxBX+clearance+wt-pryD/2, boardCenterY, pryD*2, pryW, snapHeight*3)
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fmt.Fprintf(f, "}\n\n")
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if isTray {
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// --- TRAY ---
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fmt.Fprintf(f, "// --- TRAY ---\n")
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fmt.Fprintf(f, "difference() {\n")
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fmt.Fprintf(f, " union() {\n")
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fmt.Fprintf(f, " // Tray Floor (extends to clearance + 2*wt so it is flush with enclosure outside)\n")
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fmt.Fprintf(f, " linear_extrude(height=%f) offset(r=%f) board_polygon();\n", trayFloor, clearance+2*wt)
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fmt.Fprintf(f, " // Tray Inner Wall (thickness wt)\n")
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fmt.Fprintf(f, " translate([0,0,%f]) linear_extrude(height=%f) difference() {\n", trayFloor, snapHeight)
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fmt.Fprintf(f, " offset(r=%f) board_polygon();\n", clearance+wt)
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fmt.Fprintf(f, " offset(r=%f) board_polygon();\n", clearance)
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fmt.Fprintf(f, " }\n")
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fmt.Fprintf(f, " // Snap Bumps (on outside of tray wall)\n")
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fmt.Fprintf(f, " translate([0,0,%f]) linear_extrude(height=%f) difference() {\n", trayFloor+snapHeight-0.6, 0.4)
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fmt.Fprintf(f, " offset(r=%f) board_polygon();\n", clearance+wt+0.4)
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fmt.Fprintf(f, " offset(r=%f) board_polygon();\n", clearance+wt)
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fmt.Fprintf(f, " }\n")
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fmt.Fprintf(f, " // Mounting Pegs\n")
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for _, hole := range holes {
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if hole.Type != DrillTypeMounting {
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continue
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}
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pegRadius := (hole.Diameter / 2.0) - 0.15
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fmt.Fprintf(f, " translate([%f,%f,0]) cylinder(h=%f, r=%f, $fn=32);\n", hole.X, hole.Y, totalH-lidThick, pegRadius)
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}
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fmt.Fprintf(f, " }\n")
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fmt.Fprintf(f, " // Subtract Lip Recess (for easy opening)\n")
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fmt.Fprintf(f, " translate([0,0,-1]) linear_extrude(height=%f) difference() {\n", trayFloor+lipH+0.5)
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fmt.Fprintf(f, " offset(r=%f) board_polygon();\n", clearance+2*wt+1.0)
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fmt.Fprintf(f, " offset(r=%f) board_polygon();\n", clearance+2*wt-0.5) // Assuming lipCut is 0.5mm
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fmt.Fprintf(f, " }\n")
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// Remove peg holes from floor
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for _, hole := range holes {
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if hole.Type != DrillTypeMounting {
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continue
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}
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socketRadius := (hole.Diameter / 2.0) + 0.1
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fmt.Fprintf(f, " translate([%f,%f,-1]) cylinder(h=%f, r=%f, $fn=32);\n", hole.X, hole.Y, trayFloor+2, socketRadius)
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}
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fmt.Fprintf(f, " pry_slots();\n")
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fmt.Fprintf(f, " side_cutouts();\n")
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fmt.Fprintf(f, "}\n\n")
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} else {
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// --- ENCLOSURE ---
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fmt.Fprintf(f, "// --- ENCLOSURE ---\n")
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fmt.Fprintf(f, "difference() {\n")
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fmt.Fprintf(f, " union() {\n")
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fmt.Fprintf(f, " // Outer Enclosure block (accommodates Tray Wall + Enclosure Wall)\n")
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fmt.Fprintf(f, " translate([0,0,%f]) linear_extrude(height=%f) offset(r=%f) board_polygon();\n", trayFloor, totalH-trayFloor, clearance+2*wt)
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fmt.Fprintf(f, " }\n")
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fmt.Fprintf(f, " // Subtract Inner Cavity (Base clearance around board)\n")
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fmt.Fprintf(f, " translate([0,0,-1]) linear_extrude(height=%f) offset(r=%f) board_polygon();\n", totalH-lidThick+1, clearance)
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fmt.Fprintf(f, " // Subtract Tray Recess (Accommodates Tray Wall)\n")
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fmt.Fprintf(f, " translate([0,0,-1]) linear_extrude(height=%f) offset(r=%f) board_polygon();\n", trayFloor+snapHeight+0.2, clearance+wt+0.15)
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fmt.Fprintf(f, " // Subtract Snap Groove\n")
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fmt.Fprintf(f, " translate([0,0,%f]) linear_extrude(height=%f) difference() {\n", trayFloor+snapHeight-0.7, 0.6)
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fmt.Fprintf(f, " offset(r=%f) board_polygon();\n", clearance+wt+0.5)
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fmt.Fprintf(f, " offset(r=%f) board_polygon();\n", clearance+wt)
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fmt.Fprintf(f, " }\n")
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fmt.Fprintf(f, " pry_slots();\n")
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fmt.Fprintf(f, " side_cutouts();\n")
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fmt.Fprintf(f, "}\n")
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fmt.Fprintf(f, "mounting_pegs(false);\n")
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}
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return nil
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}
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