Gira Plate Nintendo Connectors

Gira55NintendoPlate.scad

/* 
 * One-Piece Gira System 55 Frame + Integrated Dual NES/SNES Classic Plate
 * (Hollow Shell, Solid Outer Wall) + Configurable Labels + Front Bezel + Rear Collar
 *
 * - Solid, full-height outer perimeter wall (no inset at the edge)
 * - Hollow interior with thin top skin (web) + localized ribs (plate ring, connector boss rings)
 * - Rear connector collar (deep sleeve into the hollow back)
 * - Front bezel recess around each connector (2D annulus, depth + optional chamfer via scale)
 * - True through-cut connector holes with bottom INSET notch
 * - Equal margins on the 55×55 plate area
 *
 * FIX: Front bezel recess now respects the bottom inset notch (does NOT clip it).
 * FIX: Replaced ternary module-call with if/else to satisfy OpenSCAD parser.
 *
 * Author: ERDesigns — License: MIT
 */

$fn = 128; // rendering quality


//=============================== Public API ==================================//

/**
 * Builds a one-piece Gira System 55 style part:
 * - Full-height solid outer wall of width `outer_wall_w` (continuous side wall).
 * - Hollow interior capped by thin top skin (`top_skin_t`).
 * - Localized ribs: plate ring & connector boss rings.
 * - Two Wii-extension (NES/SNES Classic) through cutouts (with bottom inset notch).
 * - Optional labels above the left/right connector (emboss or inset).
 * - Rear connector collars (deep sleeves) and front bezel recesses.
 *
 * Z layout:
 *   z = 0 .................................. open back (hollow)
 *   0 .. rib heights ........................ ribs (plate ring / boss rings / rear collars)
 *   rib_max .. rib_max+top_skin_t ........... thin top skin (web)
 *   outer wall .............................. extruded from z=0 to z=top(front) (full-height)
 */
module system55_shell_onepiece(
  // Outer frame (Gira)
  outer_w            = 80.8,
  outer_corner_r     = 2.0,
  outer_roundover_r  = 1.0,
  outer_wall_w       = 10.0,     // full-height solid perimeter wall width

  // Integrated plate zone (System 55)
  plate_w            = 55.0,
  plate_corner_r     = 2.0,
  plate_recess       = 0.0,      // set >0 to recess the whole 55×55 area

  // Shell & ribs
  top_skin_t         = 1.6,      // thin web thickness
  plate_ring_w       = 4.0,      // ring width around 55×55 zone
  plate_ring_h       = 2.0,      // ring height
  boss_ring_w        = 2.0,      // radial boss width around each connector profile
  boss_ring_h        = 2.0,      // boss height

  // Rear deep collar around each connector
  rear_collar_w      = 2.5,      // radial width of the rear sleeve
  rear_collar_h      = 4.0,      // depth into the hollow

  // Front bezel recess around each connector
  front_bezel_w      = 2.0,      // radial width (≈ “rand 2 mm”)
  front_bezel_depth  = 1.0,      // recess depth (≈ 1 mm)
  front_bezel_ch_h   = 0.4,      // chamfer/taper height (0 disables)
  front_bezel_ch_scale = 1.08,   // taper scale (top slightly wider)

  // Connectors
  cutout_cfg         = make_connector(),
  y_offset           = 0.0,
  add_pilots         = false,

  // Safety for spacing math
  min_wall           = 3.0,

  // Labels
  label_enable       = true,
  label_left         = "Player 1",
  label_right        = "Player 2",
  label_font         = "DejaVu Sans:style=Bold",
  label_size         = 6.0,
  label_height       = 0.8,      // used when label_mode="emboss"
  label_depth        = 0.6,      // used when label_mode="inset"
  label_gap          = 1.6,
  label_mode         = "emboss", // "emboss" | "inset"
  label_dx_left      = 0.0,
  label_dx_right     = 0.0
){
  // ---------- Equal horizontal margins on the 55×55 plate ----------
  w_open    = get(cutout_cfg,"w") + 2*get(cutout_cfg,"bezel_extra");
  M_nominal = (plate_w - 2*w_open) / 3;     // left = mid = right
  M         = max(M_nominal, min_wall);

  // ---------- Z-stack parameters ----------
  rib_max   = max(plate_ring_h, max(boss_ring_h, rear_collar_h)); // include rear collar in rib_max
  skin_z0   = rib_max;                  // bottom of the top skin
  skin_z1   = rib_max + top_skin_t;     // top/front surface

  // ---------- Through-cut parameters (guaranteed through-hole) ----------
  cut_start_z = -0.6;                   // start slightly below the back plane
  cut_depth   = skin_z1 - cut_start_z + 0.6;

  // ---------- Inner opening size bounded by the outer wall ----------
  inner_w    = outer_w - 2*outer_wall_w;
  inner_r    = max(outer_corner_r - outer_wall_w, 0);

  // ---------- Connector vertical geometry (for labels & bezels) ----------
  h_open     = get(cutout_cfg,"h") + 2*get(cutout_cfg,"bezel_extra");

  // Front top surface where labels/bezel start
  front_top_z = (plate_recess > 0) ? (skin_z1 - plate_recess) : skin_z1;

  // Label baseline Y position (above connector)
  label_baseline_y = y_offset + (h_open/2) + label_gap;

  difference(){
    // ---------------- SOLID: wall + ribs + top skin + (emboss labels) + (rear collars) ----------------
    union(){
      // (A) Full-height solid outer wall
      linear_extrude(height=skin_z1)
        difference(){
          rounded_rect2d(outer_w, outer_w, outer_corner_r);
          rounded_rect2d(inner_w, inner_w, inner_r);
        }

      // (B) Top skin over interior area
      translate([0,0,skin_z0])
        linear_extrude(height=top_skin_t)
          rounded_rect2d(inner_w, inner_w, inner_r);

      // (C) Plate ring rib
      if (plate_ring_h > 0 && plate_ring_w > 0)
        translate([0,0,0])
          linear_extrude(height=plate_ring_h)
            difference(){
              rounded_rect2d(plate_w + 2*plate_ring_w, plate_w + 2*plate_ring_w, plate_corner_r + plate_ring_w);
              rounded_rect2d(plate_w,                   plate_w,                   plate_corner_r);
            }

      // (D) Connector boss rings (inside, below the skin)
      if (boss_ring_h > 0 && boss_ring_w > 0){
        boss_ring_at(cutout_cfg, - (w_open + M)/2, y_offset, boss_ring_w, boss_ring_h);
        boss_ring_at(cutout_cfg, + (w_open + M)/2, y_offset, boss_ring_w, boss_ring_h);
      }

      // (E) Rear deep collars (extend further inward into the hollow back)
      if (rear_collar_h > 0 && rear_collar_w > 0){
        rear_collar_at(cutout_cfg, - (w_open + M)/2, y_offset, rear_collar_w, rear_collar_h);
        rear_collar_at(cutout_cfg, + (w_open + M)/2, y_offset, rear_collar_w, rear_collar_h);
      }

      // (F) Emboss labels (if chosen)
      if (label_enable && label_size > 0 && label_mode == "emboss" && label_height > 0){
        x_left  = - (w_open + M)/2 + label_dx_left;
        x_right = + (w_open + M)/2 + label_dx_right;

        embossed_label(label_left,  x_left,  label_baseline_y, front_top_z, label_size, label_height, label_font);
        embossed_label(label_right, x_right, label_baseline_y, front_top_z, label_size, label_height, label_font);
      }
    }

    // ---------------- OPTIONAL: recess into the top skin (plate area) ----------------
    if (plate_recess > 0){
      recess_h = min(plate_recess, top_skin_t - 0.2); // keep ≥0.2 mm skin floor
      if (recess_h > 0)
        translate([0,0,skin_z1 - recess_h])
          linear_extrude(height=recess_h)
            rounded_rect2d(plate_w, plate_w, plate_corner_r);
    }

    // ---------------- CONNECTOR CUTOUTS (true through) ----------------
    translate([-(w_open + M)/2, y_offset, cut_start_z])
      connector_cutout(cutout_cfg, cut_depth, add_pilots);
    translate([ +(w_open + M)/2, y_offset, cut_start_z])
      connector_cutout(cutout_cfg, cut_depth, add_pilots);

    // ---------------- INSET LABELS (engrave) ----------------
    if (label_enable && label_size > 0 && label_mode == "inset" && label_depth > 0){
      x_left  = - (w_open + M)/2 + label_dx_left;
      x_right = + (w_open + M)/2 + label_dx_right;

      engraved_label(label_left,  x_left,  label_baseline_y, front_top_z, label_size, label_depth, label_font);
      engraved_label(label_right, x_right, label_baseline_y, front_top_z, label_size, label_depth, label_font);
    }

    // ---------------- FRONT BEZEL RECESS (notch-safe) ----------------
    if (front_bezel_depth > 0 && front_bezel_w > 0){
      // Clamp recess to skin thickness to avoid punching through the skin
      bezel_h = min(front_bezel_depth, top_skin_t - 0.2);  // keep ≥0.2 mm floor
      if (bezel_h > 0){
        // Main recess annulus (inner boundary follows the REAL hole incl. bottom notch)
        front_bezel_at(cutout_cfg, - (w_open + M)/2, y_offset, front_top_z, front_bezel_w, bezel_h, 1.0, notch_safe=true);
        front_bezel_at(cutout_cfg, + (w_open + M)/2, y_offset, front_top_z, front_bezel_w, bezel_h, 1.0, notch_safe=true);

        // Optional chamfer/taper (scaled recess) directly at the top, also notch-safe
        if (front_bezel_ch_h > 0 && front_bezel_ch_scale > 1.0){
          ch_h = min(front_bezel_ch_h, top_skin_t - 0.2);
          if (ch_h > 0){
            front_bezel_at(cutout_cfg, - (w_open + M)/2, y_offset, front_top_z, front_bezel_w, ch_h, front_bezel_ch_scale, notch_safe=true);
            front_bezel_at(cutout_cfg, + (w_open + M)/2, y_offset, front_top_z, front_bezel_w, ch_h, front_bezel_ch_scale, notch_safe=true);
          }
        }
      }
    }
  }
}


//==================== Helpers: boss ring / collars / labels / bezel ==========//

/** Creates one connector boss ring at (xc, yc) with given ring width/height. */
module boss_ring_at(cfg, xc, yc, ring_w, ring_h){
  translate([xc, yc, 0])
    linear_extrude(height=ring_h)
      connector_ring_annulus_2d(cfg, ring_w);
}

/** Rear deep collar (longer sleeve) at (xc, yc) extending deeper into the hollow back. */
module rear_collar_at(cfg, xc, yc, collar_w, collar_h){
  translate([xc, yc, 0])
    linear_extrude(height=collar_h)
      connector_ring_annulus_2d(cfg, collar_w);
}

/**
 * Front bezel recess around the connector hole.
 * Subtracts an annular region starting at the top surface (front_top_z) downward by `bezel_h`.
 * If `scale_factor` > 1, a slight taper is created (wider at the top).
 * If `notch_safe` is true, the inner boundary follows the REAL hole incl. bottom notch,
 * so the notch is preserved.
 */
module front_bezel_at(cfg, xc, yc, front_top_z, bezel_w, bezel_h, scale_factor=1.0, notch_safe=true){
  translate([xc, yc, front_top_z - bezel_h])
    linear_extrude(height=bezel_h + 0.02, scale=scale_factor)
      if (notch_safe)
        connector_ring_annulus_with_notch_2d(cfg, bezel_w);
      else
        connector_ring_annulus_2d(cfg, bezel_w);
}

/** 2D ring helper: offset(+ring_w) of connector profile (WITHOUT notch) minus base profile. */
module connector_ring_annulus_2d(cfg, ring_w){
  difference(){
    offset(delta=ring_w) connector_profile_2d(cfg);
    connector_profile_2d(cfg);
  }
}

/** 2D ring helper using the REAL hole profile INCLUDING the bottom inset notch. */
module connector_ring_annulus_with_notch_2d(cfg, ring_w){
  difference(){
    offset(delta=ring_w) connector_profile_with_notch_2d(cfg);
    connector_profile_with_notch_2d(cfg);
  }
}

/** Adds raised text at (xc, y_base) on top surface z=text_z. */
module embossed_label(txt, xc, y_base, text_z, size, height, font_name){
  if (txt != "" && height > 0 && size > 0)
    translate([xc, y_base, text_z])
      linear_extrude(height=height)
        text(text=txt, size=size, font=font_name, halign="center", valign="baseline", $fn=64);
}

/** Subtracts (engraves) text into the top surface by `depth`. */
module engraved_label(txt, xc, y_base, text_z, size, depth, font_name){
  if (txt != "" && depth > 0 && size > 0)
    translate([xc, y_base, text_z - depth])
      linear_extrude(height=depth + 0.02)
        text(text=txt, size=size, font=font_name, halign="center", valign="baseline", $fn=64);
}


//=========================== Connector profile ===============================//

/**
 * NES/SNES Classic (Wii-extension) connector opening config.
 * (Your latest values are used in the preset below.)
 *
 * @param w,h,r,bezel_extra  Body size and clearance.
 * @param bottom_slot_*      Bottom INSET notch (bites upward into the opening).
 */
function make_connector(
  w=15.5, h=10.5, r=1.0, bezel_extra=0.30,
  left_notch_w=2.2,  left_notch_h=1.8,  left_notch_y=0.0,
  right_notch_w=2.2, right_notch_h=1.8, right_notch_y=0.0,
  notch_r=0.6,
  chamfer=0.6,
  bottom_slot_w=3.1,
  bottom_slot_h=2.5,
  bottom_slot_r=0.6
) = [
  ["w", w], ["h", h], ["r", r], ["bezel_extra", bezel_extra],
  ["left_notch_w", left_notch_w], ["left_notch_h", left_notch_h], ["left_notch_y", left_notch_y],
  ["right_notch_w", right_notch_w], ["right_notch_h", right_notch_h], ["right_notch_y", right_notch_y],
  ["notch_r", notch_r],
  ["chamfer", chamfer],
  ["bottom_slot_w", bottom_slot_w],
  ["bottom_slot_h", bottom_slot_h],
  ["bottom_slot_r", bottom_slot_r]
];

/** 2D union of the connector opening WITHOUT the bottom inset notch. */
module connector_profile_2d(cfg){
  w  = get(cfg,"w");  h  = get(cfg,"h");  rr = get(cfg,"r");
  bezel = get(cfg,"bezel_extra");
  lnw = get(cfg,"left_notch_w");  lnh = get(cfg,"left_notch_h");  lny = get(cfg,"left_notch_y");
  rnw = get(cfg,"right_notch_w"); rnh = get(cfg,"right_notch_h"); rny = get(cfg,"right_notch_y");
  nr  = get(cfg,"notch_r");

  union(){
    rounded_rect2d(w + 2*bezel, h + 2*bezel, rr);
    if (lnw > 0 && lnh > 0)
      translate([-(w/2 + bezel - 0.01), lny])
        translate([-lnw/2, 0])
          rounded_rect2d(lnw, lnh, nr);
    if (rnw > 0 && rnh > 0)
      translate([(w/2 + bezel - 0.01), rny])
        translate([+rnw/2, 0])
          rounded_rect2d(rnw, rnh, nr);
  }
}

/**
 * 2D union of the REAL connector opening INCLUDING the bottom inset notch.
 * This matches the actual through-hole outline at the top surface (so bezel doesn’t clip the notch).
 */
module connector_profile_with_notch_2d(cfg){
  w  = get(cfg,"w");  h  = get(cfg,"h");  rr = get(cfg,"r");
  bezel = get(cfg,"bezel_extra");
  lnw = get(cfg,"left_notch_w");  lnh = get(cfg,"left_notch_h");  lny = get(cfg,"left_notch_y");
  rnw = get(cfg,"right_notch_w"); rnh = get(cfg,"right_notch_h"); rny = get(cfg,"right_notch_y");
  nr  = get(cfg,"notch_r");
  bsw = get(cfg,"bottom_slot_w");
  bsh = get(cfg,"bottom_slot_h");
  bsr = get(cfg,"bottom_slot_r");

  difference(){
    // Base opening (union of main + side key enlargements)
    union(){
      rounded_rect2d(w + 2*bezel, h + 2*bezel, rr);
      if (lnw > 0 && lnh > 0)
        translate([-(w/2 + bezel - 0.01), lny])
          translate([-lnw/2, 0])
            rounded_rect2d(lnw, lnh, nr);
      if (rnw > 0 && rnh > 0)
        translate([(w/2 + bezel - 0.01), rny])
          translate([+rnw/2, 0])
            rounded_rect2d(rnw, rnh, nr);
    }
    // Subtract the bottom inset notch (the “bite” into the opening)
    if (bsw > 0 && bsh > 0)
      translate([0, -(h/2 + bezel) + bsh/2])
        rounded_rect2d(bsw, bsh, bsr);
  }
}

/** Subtracts the connector profile with an INSET bottom notch (true through-hole). */
module connector_cutout(cfg, depth, pilots=false){
  w  = get(cfg,"w");  h  = get(cfg,"h");  rr = get(cfg,"r");
  bezel = get(cfg,"bezel_extra");
  lnw = get(cfg,"left_notch_w");  lnh = get(cfg,"left_notch_h");  lny = get(cfg,"left_notch_y");
  rnw = get(cfg,"right_notch_w"); rnh = get(cfg,"right_notch_h"); rny = get(cfg,"right_notch_y");
  nr  = get(cfg,"notch_r");
  chamfer = get(cfg,"chamfer");
  bsw = get(cfg,"bottom_slot_w");
  bsh = get(cfg,"bottom_slot_h");
  bsr = get(cfg,"bottom_slot_r");

  difference(){
    // 3D extrusion of composite hole (base + side enlargements) MINUS bottom notch
    linear_extrude(height=depth)
      difference(){
        union(){
          rounded_rect2d(w + 2*bezel, h + 2*bezel, rr);
          if (lnw > 0 && lnh > 0)
            translate([-(w/2 + bezel - 0.01), lny])
              translate([-lnw/2, 0])
                rounded_rect2d(lnw, lnh, nr);
          if (rnw > 0 && rnh > 0)
            translate([(w/2 + bezel - 0.01), rny])
              translate([+rnw/2, 0])
                rounded_rect2d(rnw, rnh, nr);
        }
        if (bsw > 0 && bsh > 0)
          translate([0, -(h/2 + bezel) + bsh/2])
            rounded_rect2d(bsw, bsh, bsr);
      }

    if (pilots){
      linear_extrude(height=depth) square([w, 0.2], center=true);
      linear_extrude(height=depth) square([0.2, h], center=true);
    }
  }

  // Cosmetic micro-chamfer at the very front edge of the hole
  if (chamfer > 0){
    translate([0,0,-0.01])
      linear_extrude(height=chamfer)
        offset(delta=+chamfer)
          rounded_rect2d(w + 2*bezel, h + 2*bezel, rr);
  }
}


//============================= Geometry helpers ==============================//

/** 2D rounded rectangle helper. */
module rounded_rect2d(w, h, r){
  offset(r=r) offset(r=-r) square([w-2*r, h-2*r], center=true);
}

/** 3D rounded rectangle helper (straight sides). */
module rounded_rect3d(w, h, t, r){
  linear_extrude(height=t) rounded_rect2d(w, h, r);
}

/**
 * Builds a slab with a TRUE round-over on the outer top front edge.
 * Implemented via minkowski() then clipped to height t.
 */
module rounded_face3d(w, h, t, corner_r_2d, roundover_r){
  if (roundover_r <= 0){
    rounded_rect3d(w, h, t, corner_r_2d);
  } else {
    intersection(){
      translate([0,0,t/2]) cube([w*2, h*2, t], center=true);
      minkowski(){
        linear_extrude(height = max(t - roundover_r, 0.01))
          rounded_rect2d(w, h, corner_r_2d);
        sphere(r = roundover_r);
      }
    }
  }
}

/** Tiny key-value getter for our struct-like vectors. */
function get(cfg, key, default_val=0) =
  let(idx = search([key], [ for (i=[0:len(cfg)-1]) cfg[i][0] ])[0])
  (idx==[]) ? default_val : cfg[idx][1];


//============================= PRESET & RENDER ===============================//

/** Gira System 55 shell preset incl. labels, rear collars and front bezels (notch-safe). */
module gira_system55_shell_preset(){
  system55_shell_onepiece(
    // Outer aesthetics
    outer_w            = 80.8,
    outer_corner_r     = 2.0,
    outer_roundover_r  = 1.0,
    outer_wall_w       = 10.0,

    // Plate zone
    plate_w            = 55.0,
    plate_corner_r     = 2.0,
    plate_recess       = 0.0,

    // Shell & ribs
    top_skin_t         = 1.6,
    plate_ring_w       = 4.0,
    plate_ring_h       = 2.0,
    boss_ring_w        = 2.0,
    boss_ring_h        = 2.0,

    // Rear collars
    rear_collar_w      = 2.5,
    rear_collar_h      = 4.0,

    // Front bezel recess (+ optional chamfer)
    front_bezel_w      = 2.0,
    front_bezel_depth  = 1.0,
    front_bezel_ch_h   = 0.4,
    front_bezel_ch_scale = 1.08,

    // Connectors (your current params)
    cutout_cfg         = connector_cfg,
    y_offset           = 0.0,
    add_pilots         = false,
    min_wall           = 3.0,

    // Labels
    label_enable       = true,
    label_left         = "Player 1",
    label_right        = "Player 2",
    label_font         = "DejaVu Sans:style=Bold",
    label_size         = 4.0,
    label_height       = 0.8,
    label_depth        = 0.6,
    label_gap          = 3.5,
    label_mode         = "inset",
    label_dx_left      = 0.0,
    label_dx_right     = 0.0
  );
}

// --- Connector tuning (your latest values) ---
connector_cfg = make_connector(
  w=17.0, h=12.0, r=1.0, bezel_extra=0.30,
  left_notch_w=2.2,  left_notch_h=1.8,  left_notch_y=0.0,
  right_notch_w=2.2, right_notch_h=1.8, right_notch_y=0.0,
  notch_r=0.6,
  chamfer=0.6,
  bottom_slot_w=3.1,
  bottom_slot_h=2.5,
  bottom_slot_r=0.6
);

// ---------------------- RENDER ----------------------
gira_system55_shell_preset();