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Bernd Mueller
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chip_handle.scad
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180
chip_handle.scad
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/*
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================================================================================
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ATARI & FIREBEE SHOPPING TROLLEY KEY (Multi-Material Edition)
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Version: 3.2.0
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License: Creative Commons - Attribution - Non-Commercial - Share Alike (CC-BY-NC-SA)
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================================================================================
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USER MANUAL:
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1. Ensure the following SVG files are in the same folder as this .scad file:
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- logo_atari.svg (Front side of the round chip)
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- logo_firebee.svg (Back side of the round chip)
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- logo_text.svg (Back side on the handle/grip)
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2. Use the 'export_mode' variable below to switch between parts for export.
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3. For a multi-color print on the AD5X:
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- Set export_mode = "chip"; -> Render (F6) -> Export STL as 'base.stl'
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- Set export_mode = "atari"; -> Render (F6) -> Export STL as 'inlay_atari.stl'
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- Set export_mode = "firebee"; -> Render (F6) -> Export STL as 'inlay_firebee.stl'
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- Set export_mode = "text"; -> Render (F6) -> Export STL as 'inlay_text.stl'
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4. Import all 4 STLs into your slicer (e.g., OrcaSlicer) simultaneously.
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5. When asked "Load as a single object with multiple parts?", select YES.
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6. Assign your 4 filaments to the respective parts.
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OPTIMAL PRINT SETTINGS (0.4mm Nozzle):
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- Layer Height: 0.15mm (0.2mm for first layer)
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- Wall Loops: 4 (Crucial for mechanical strength of the chip and keyhole)
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- Top/Bottom Shells: 5
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- Infill: 30% (Gyroid or Honeycomb recommended)
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- First Layer Speed: 15-20 mm/s (Slow is vital for the fine inlays on the bed)
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- Cooling: 100% after layer 2
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- Prime Tower: Enabled (To prevent color bleeding between the 4 colors)
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- Z-Hop: 0.4mm (Prevents the nozzle from scarring finished color areas)
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================================================================================
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*/
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// --- GLOBAL SETTINGS ---
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$fn = 100; // Detail level for circular geometries
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// --- EXPORT CONTROL ---
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// "preview" -> Visualizes all colors together
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// "chip" -> The main body with all hollowed-out pockets
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// "atari" -> The inlay for the front Atari logo
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// "firebee" -> The inlay for the back Firebee logo
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// "text" -> The inlay for the text on the handle
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export_mode = "preview";
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// --- DIMENSIONS & PARAMETERS ---
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chip_radius = 11.5; // Standard 23mm diameter
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chip_height = 2.4; // Total thickness
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logo_depth = 0.6; // Depth of the engravings (approx. 4 layers at 0.15mm)
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max_logo_size = (chip_radius * 2) * 0.70; // Scaling factor for round logos
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// Handle (Grip) Parameters
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handle_length = 45; // Length from the bottom edge of the chip to the end
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handle_width = 16; // Width of the rectangular grip
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handle_corner_radius = 3;
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taper_start_y = -7.5; // Y-coordinate where the chip begins to taper into the handle
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hole_diameter = 5;
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hole_offset_bottom = 7; // Hole center distance from the bottom edge
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// Margin & Spacing for handle text
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handle_margin = 2;
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hole_clearance = 2; // Space between the hole and the text
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taper_clearance = 2; // Space before the handle tapers into the chip
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// --- FILENAMES ---
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file_atari = "logo_atari.svg";
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file_firebee = "logo_firebee.svg";
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file_text = "logo_text.svg";
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// --- CALCULATIONS FOR TEXT PLACEMENT ---
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hole_top_edge_y = (-chip_radius - handle_length + hole_offset_bottom) + (hole_diameter/2);
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text_limit_bottom = hole_top_edge_y + hole_clearance;
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text_limit_top = taper_start_y - taper_clearance;
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available_text_length = abs(text_limit_top - text_limit_bottom);
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text_y_position = text_limit_bottom + (available_text_length / 2);
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// --- LOGO MODULES (2D DEFINITIONS) ---
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module module_logo_atari() {
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render()
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translate([0, 2, 0]) // Manual alignment for specific SVG geometry
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resize([max_logo_size, max_logo_size, 0], auto=true)
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offset(delta = 0.01) // Closes paths to prevent mesh errors
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import(file_atari, center = true);
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}
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module module_logo_firebee() {
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render()
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// Mirroring on the Y-axis (vertical) so it "flies up" on the back side
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// mirror([0, 1, 0])
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resize([max_logo_size, max_logo_size, 0], auto=true)
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offset(delta = 0.01)
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import(file_firebee, center = true);
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}
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module module_logo_text() {
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render()
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mirror([1, 0, 0]) // Mirror for correct legibility on the bottom side
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rotate([0, 0, 90]) // Rotate to align with handle axis
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// Resize to fit perfectly within calculated handle area
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resize([available_text_length, handle_width - (2 * handle_margin), 0], auto=true)
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offset(delta = 0.01)
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import(file_text, center = true);
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}
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// --- GEOMETRY MODULES ---
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module module_handle_shape() {
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difference() {
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hull() {
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// Chord calculation: circle width at taper start point
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chord_length = 2 * sqrt(pow(chip_radius, 2) - pow(taper_start_y, 2));
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translate([-chord_length/2, taper_start_y - 0.1, -chip_height/2])
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cube([chord_length, 0.1, chip_height]);
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// Rounded end of the handle
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end_y_pos = -chip_radius - handle_length + handle_corner_radius;
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translate([-(handle_width/2 - handle_corner_radius), end_y_pos, 0])
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cylinder(h = chip_height, r = handle_corner_radius, center = true);
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translate([(handle_width/2 - handle_corner_radius), end_y_pos, 0])
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cylinder(h = chip_height, r = handle_corner_radius, center = true);
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}
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// Keyhole subtraction
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translate([0, -chip_radius - handle_length + hole_offset_bottom, 0])
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cylinder(h = chip_height + 2, r = hole_diameter/2, center = true);
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}
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}
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// --- FINAL ASSEMBLY ---
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// 1. MAIN KEY BODY (Chip and handle with engraved pockets)
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if (export_mode == "preview" || export_mode == "chip") {
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difference() {
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union() {
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color("Grey") cylinder(h = chip_height, r = chip_radius, center = true);
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color("Grey") module_handle_shape();
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}
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// Pocket for Atari (Top)
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translate([0, 0, chip_height/2 - logo_depth + 0.01])
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linear_extrude(height = logo_depth + 0.1, convexity = 10)
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module_logo_atari();
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// Pocket for Firebee (Bottom)
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translate([0, 0, -chip_height/2 - 0.1])
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linear_extrude(height = logo_depth + 0.1, convexity = 10)
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module_logo_firebee();
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// Pocket for Text (Bottom)
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translate([0, text_y_position, -chip_height/2 - 0.1])
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linear_extrude(height = logo_depth + 0.1, convexity = 10)
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module_logo_text();
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}
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}
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// 2. ATARI INLAY (Top Color)
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if (export_mode == "preview" || export_mode == "atari") {
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color("Cyan") translate([0, 0, chip_height/2 - logo_depth])
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linear_extrude(height = logo_depth, convexity = 10)
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module_logo_atari();
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}
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// 3. FIREBEE INLAY (Bottom Color A)
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if (export_mode == "preview" || export_mode == "firebee") {
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color("Orange") translate([0, 0, -chip_height/2])
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linear_extrude(height = logo_depth, convexity = 10)
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module_logo_firebee();
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}
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// 4. HANDLE TEXT INLAY (Bottom Color B)
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if (export_mode == "preview" || export_mode == "text") {
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color("Lime") translate([0, text_y_position, -chip_height/2])
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linear_extrude(height = logo_depth, convexity = 10)
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module_logo_text();
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}
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