Through Desk Nintendo Connector SCAD

ThroughDeskNintendo.scad

/* 
 * Integrated Round Through-Desk Dual NES/SNES Classic Panel (One-Piece)
 * - Circular cover (flush with desktop) + cylindrical sleeve; printed as a single piece
 * - Two NES/SNES Classic female cutouts in the cover (notch-safe)
 * - Structural underside: connector lip (downward continuation of the female opening) + optional rings
 * - Optional labels above each connector (emboss or inset)
 * - No fasteners
 *
 * Author: ERDesigns — License: MIT
 */

$fn = 128; // rendering quality


//============================== Global scale =================================//

/**
 * /// <summary>
 * /// Global export scale to compensate slicer/CAD unit mismatch.
 * /// Example: if slicer shows 76 mm where 80 mm is expected, set export_scale = 80/76.
 * /// </summary>
 */
export_scale = 1.0;

/** /// <summary>Render helper applying export_scale only.</summary> */
module scaled(){ scale([export_scale, export_scale, export_scale]) children(); }


//============================== Public parameters ============================//

/** /// <summary>Cover (top plate) parameters.</summary> */
cover_od            = 80.0;      // visible outer diameter of the cover
cover_thickness     = 3.0;       // cover thickness (defines flush depth)
cover_roundover_r   = 5.0;       // top outer-edge roundover radius (real fillet on top rim)

/** /// <summary>Sleeve (tube) parameters.</summary> */
sleeve_od           = 60.0;      // sleeve outer diameter (independent from cover_od)
sleeve_wall         = 1.0;       // sleeve wall thickness
sleeve_extra_below  = 40.0;      // extra length below the desktop (print length under the cover)

/** /// <summary>NES/SNES connector configuration and placement.</summary> */
connector_cfg = make_connector(
  w=16.5, h=11.5, 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
);
connector_cc        = 25.0;   // center-to-center spacing along X (mm)
connector_y_offset  = 0.0;    // vertical offset of the pair (mm)

/** /// <summary>Optional shallow bezel recess on top face.</summary> */
front_bezel_depth   = 1.0;    // 0 disables
front_bezel_w       = 1.8;

/** /// <summary>Optional legacy stiffening rings (set to 0 to disable).</summary> */
boss_ring_w         = 0.0;
boss_ring_h         = 0.0;
rear_collar_w       = 0.0;
rear_collar_h       = 0.0;

/** /// <summary>Downward connector lip (notch-safe), like the Gira plate.</summary> */
connector_lip_w     = 2.0;    // radial thickness of the lip (mm)
connector_lip_h     = 4.0;    // downward height of the lip (mm)

/** /// <summary>Label settings (text above each connector on the top surface).</summary> */
label_enable        = true;
label_left          = "Player 1";
label_right         = "Player 2";
label_font          = "DejaVu Sans:style=Bold";
label_size          = 4.0;
label_mode          = "inset";    // "emboss" | "inset"
label_height        = 0.8;        // used when label_mode="emboss"
label_depth         = 0.6;        // used when label_mode="inset"
label_gap           = 3.5;        // distance from opening to text baseline (mm)
label_dx_left       = 0.0;        // fine X offset left label
label_dx_right      = 0.0;        // fine X offset right label
label_track_center  = true;       // keep centered above each connector, then add dx


//============================== Derived values ===============================//

sleeve_id   = sleeve_od - 2*sleeve_wall;
sleeve_len  = sleeve_extra_below; // sleeve extends downwards (z negative)

// Opening height incl. bezel clearance (for label baseline)
h_open      = get(connector_cfg,"h") + 2*get(connector_cfg,"bezel_extra");
label_baseline_y = connector_y_offset + (h_open/2) + label_gap;


//============================== Top-level render =============================//

scaled() unit_onepiece();

/**
 * /// <summary>
 * /// Integrated one-piece panel with: cover, sleeve, downward connector lips, optional rings, labels.
 * /// </summary>
 */
module unit_onepiece(){
  difference(){
    // ----- SOLID UNION: cover + sleeve + underside features + (emboss labels) -----
    union(){
      // (A) cover with real top roundover
      cover_with_roundover(cover_od, cover_thickness, cover_roundover_r);

      // (B) sleeve downwards from cover underside (z = [-sleeve_len, 0])
      translate([0,0,-sleeve_len])
        cylinder(h=sleeve_len, d=sleeve_od, center=false);

      // (C) downward connector lips (notch-safe)
      if (connector_lip_h > 0 && connector_lip_w > 0){
        connector_lip_at(-connector_cc/2, connector_y_offset, connector_lip_w, connector_lip_h);
        connector_lip_at(+connector_cc/2, connector_y_offset, connector_lip_w, connector_lip_h);
      }

      // (D) optional legacy stiffening rings
      if (boss_ring_h > 0 && boss_ring_w > 0){
        translate([-connector_cc/2, connector_y_offset, -boss_ring_h])
          linear_extrude(height=boss_ring_h)
            connector_ring_annulus_2d(connector_cfg, boss_ring_w);
        translate([+connector_cc/2, connector_y_offset, -boss_ring_h])
          linear_extrude(height=boss_ring_h)
            connector_ring_annulus_2d(connector_cfg, boss_ring_w);
      }
      if (rear_collar_h > 0 && rear_collar_w > 0){
        translate([-connector_cc/2, connector_y_offset, -rear_collar_h])
          linear_extrude(height=rear_collar_h)
            connector_ring_annulus_2d(connector_cfg, rear_collar_w);
        translate([+connector_cc/2, connector_y_offset, -rear_collar_h])
          linear_extrude(height=rear_collar_h)
            connector_ring_annulus_2d(connector_cfg, rear_collar_w);
      }

      // (E) Emboss labels (add material) if selected
      if (label_enable && label_size > 0 && label_mode == "emboss" && label_height > 0){
        // compute X positions using let() to avoid assignments
        let(
          xL = -connector_cc/2 + (label_track_center ? 0 : label_dx_left) + (label_track_center ? label_dx_left : 0),
          xR = +connector_cc/2 + (label_track_center ? 0 : label_dx_right) + (label_track_center ? label_dx_right : 0)
        ){
          embossed_label(label_left,  xL, label_baseline_y, cover_thickness, label_size, label_height, label_font);
          embossed_label(label_right, xR, label_baseline_y, cover_thickness, label_size, label_height, label_font);
        }
      }
    }

    // ----- CENTRAL BORE: through the SLEEVE ONLY (stops at cover underside) -----
    translate([0,0,-sleeve_len-0.05])
      cylinder(h=sleeve_len + 0.1, d=sleeve_id, center=false);

    // ----- CONNECTOR CUTOUTS: through the cover thickness only -----
    translate([-connector_cc/2, connector_y_offset, 0])
      connector_cutout(connector_cfg, cover_thickness + 0.06, false);
    translate([+connector_cc/2, connector_y_offset, 0])
      connector_cutout(connector_cfg, cover_thickness + 0.06, false);

    // ----- OPTIONAL BEZEL RECESS (shallow) on top face -----
    if (front_bezel_depth > 0 && front_bezel_w > 0){
      let(bezel_h = min(front_bezel_depth, cover_thickness - 0.3))
      if (bezel_h > 0){
        front_bezel_at(connector_cfg, -connector_cc/2, connector_y_offset, cover_thickness, front_bezel_w, bezel_h, 1.0, notch_safe=true);
        front_bezel_at(connector_cfg, +connector_cc/2, connector_y_offset, cover_thickness, front_bezel_w, bezel_h, 1.0, notch_safe=true);
      }
    }

    // ----- INSET LABELS (engraved) if selected -----
    if (label_enable && label_size > 0 && label_mode == "inset" && label_depth > 0){
      let(engr_h = min(label_depth, max(cover_thickness - 0.2, 0.01)))
      if (engr_h > 0){
        let(
          xL2 = -connector_cc/2 + (label_track_center ? 0 : label_dx_left) + (label_track_center ? label_dx_left : 0),
          xR2 = +connector_cc/2 + (label_track_center ? 0 : label_dx_right) + (label_track_center ? label_dx_right : 0)
        ){
          engraved_label(label_left,  xL2, label_baseline_y, cover_thickness, label_size, engr_h, label_font);
          engraved_label(label_right, xR2, label_baseline_y, cover_thickness, label_size, engr_h, label_font);
        }
      }
    }
  }
}


//============================== Cover geometry ===============================//

/**
 * /// <summary>
 * /// Disk-shaped cover with a TRUE top outer-edge roundover of radius r.
 * /// Uses minkowski() and intersection to avoid rounding the bottom edge.
 * /// </summary>
 */
module cover_with_roundover(d, t, r){
  r_eff = max(0, min(r, t - 0.1));     // keep a small straight section
  if (r_eff <= 0){
    cylinder(h=t, d=d, center=false);
  } else {
    intersection(){
      // Clip to exact height t so only the TOP edge is rounded
      translate([0,0,t/2]) cube([d*2, d*2, t], center=true);
      minkowski(){
        // inner core (reduced diameter so minkowski restores 'd')
        linear_extrude(height=max(t - r_eff, 0.01))
          circle(d=max(d - 2*r_eff, 0.1));
        sphere(r=r_eff);
      }
    }
  }
}


//============================== NEW: Connector lip ===========================//

/**
 * /// <summary>
 * /// Downward connector lip (notch-safe) built as a true tube wall:
 * /// outer wall = offset(+lip_w) of the real opening; inner wall = exact opening.
 * /// This guarantees the inner aperture is unchanged and all material grows outward.
 * /// </summary>
 * /// <param name="xc">X center</param>
 * /// <param name="yc">Y center</param>
 * /// <param name="lip_w">Radial wall thickness (mm)</param>
 * /// <param name="lip_h">Downward height (mm)</param>
 */
module connector_lip_at(xc, yc, lip_w, lip_h){
  if (lip_w > 0 && lip_h > 0){
    translate([xc, yc, -lip_h])
      difference(){
        // Outer shell: expanded (offset outward) real opening
        linear_extrude(height=lip_h)
          offset(delta=lip_w)
            connector_profile_with_notch_2d(connector_cfg);

        // Hollow core: exact real opening (same as cover hole), ensures no inward shrink
        linear_extrude(height=lip_h + 0.02)
          connector_profile_with_notch_2d(connector_cfg);
      }
  }
}


//============================== Labels =======================================//

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

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


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

/** /// <summary>NES/SNES Classic connector opening config (struct-like vector).</summary> */
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]
];

/** /// <summary>Tiny key-value getter for our struct-like vectors.</summary> */
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];

/** /// <summary>2D union of the connector opening WITHOUT the bottom inset notch.</summary> */
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);
  }
}

/**
 * /// <summary>
 * /// 2D union of the REAL connector opening INCLUDING the bottom inset notch
 * /// (matches the true through-hole outline at the top surface).
 * /// </summary>
 */
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(){
    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);
  }
}

/**
 * /// <summary>
 * /// Subtracts the connector profile with an INSET bottom notch (true through-hole).
 * /// Use 'depth = cover_thickness + epsilon' for cover-only subtraction.
 * /// </summary>
 */
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(){
    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
  if (chamfer > 0){
    translate([0,0,-0.01])
      linear_extrude(height=chamfer)
        offset(delta=+chamfer)
          rounded_rect2d(w + 2*bezel, h + 2*bezel, rr);
  }
}

/** /// <summary>Front bezel recess generator (notch-safe annulus).</summary> */
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);
}

/** /// <summary>Annulus helper without notch.</summary> */
module connector_ring_annulus_2d(cfg, ring_w){
  difference(){
    offset(delta=ring_w) connector_profile_2d(cfg);
    connector_profile_2d(cfg);
  }
}

/** /// <summary>Annulus helper with real notch outline.</summary> */
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);
  }
}


//============================== Utility geometry =============================//

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