// Toolcart design for milling machine - week 7 Fabacademy 2024 - e13
$fn = 40;               // drawing segments
mat = 15;               // material thickness  
mill = 5;               // used mill diameter
tab = 80;               // tab width
width = 800;            // main unit width (bottom plate)
height = 1000;          // total height (side plate)
depth = 560;            // depth (bottom plate)
corner = 60;            // corner ratio (global)
cross1 = [mat,175];     // sizes and heights for cross section panels
cross2 = [250,125];     // bottom side
cross3 = [425,125];     // ..
cross4 = [600,100];     // ..
cross5 = [750,100];     // ..
cross6 = [900,100];     // top panel
tabspacing = [60,180];  // two tabs on the groundplane at these distances
peg = 5;                // dowel size for tab-fixing
// below the different build stages:  
build(); // build the cart - the full assembled design
// color("yellow")cube([1700,1220,1]); // base material (for reference)
// flat(); // all components on one pane
// projection()flat(); // make a flat SVG projection
// testcut();  // make a small test piece to test the tab fitting
// experimental: the following generates an offset cut-path (not needed for Vcarve)
// color("red")translate([0,0,8])cutpath_buildplate(); 
module cutpath_buildplate(){
    translate([40,670,0])difference(){
        offset(r=mill/2,chamfer = true)projection()sidepanel(depth,height,180,180,corner);
        offset(r=-mill/2,chamfer = true)projection()sidepanel_cutshapes(depth);
    }
    translate([1320,1020,0])rotate([0,0,180])difference(){
        offset(r=mill/2,chamfer = true)projection()sidepanel(depth,height,180,180,corner);
        offset(r=-mill/2,chamfer = true)projection()sidepanel_cutshapes(depth);
    }
    translate([20,20,0])difference(){
        offset(r=mill/2,chamfer = true)projection()bottomplate(width,depth,400,150,corner);
        offset(r=-mill/2,chamfer = true)projection()bottom_cutshapes(width,depth);
    }
    translate([1540,440,0])rotate([0,0,90])offset(r=mill/2,chamfer = true)projection()crosspanel(width-4*mat,cross1[1]);
    translate([900,20,0])offset(r=mill/2,chamfer = true)projection()crosspanel(width-4*mat,cross2[1]);
    translate([1680,440,0])rotate([0,0,90])offset(r=mill/2,chamfer = true)projection()crosspanel(width-4*mat,cross3[1]);
    translate([900,160,0])offset(r=mill/2,chamfer = true)projection()crosspanel(width-4*mat,cross4[1]);
    translate([400,1080,0])offset(r=mill/2,chamfer = true)projection()crosspanel(width-4*mat,cross5[1]);
    translate([900,280,0])offset(r=mill/2,chamfer = true)projection()crosspanel(width-4*mat,cross6[1]);
}
module testcut(){
    projection(){
        millslot(80);
        translate([40,0,0])tab(80);
        translate([40+mat,-10,0])cube([10,100,mat]);    
    }
}
module build(){
    bottomplate(width,depth,400,150,corner); // todo: replace fixed sizes by ratios
    translate([2*mat,0,mat])rotate([0,-90,0])sidepanel(depth,height,180,180,corner); 
    translate([width-mat,0,mat])rotate([0,-90,0])sidepanel(depth,height,180,180,corner);
    // cross section plates
    translate([2*mat,depth/2+mat/2,cross1[0]])rotate([90,0,0])crosspanel(width-4*mat,cross1[1]);
    translate([2*mat,depth/2+mat/2,cross2[0]])rotate([90,0,0])crosspanel(width-4*mat,cross2[1]);
    translate([2*mat,depth/2+mat/2,cross3[0]])rotate([90,0,0])crosspanel(width-4*mat,cross3[1]);
    translate([2*mat,depth/2+mat/2,cross4[0]])rotate([90,0,0])crosspanel(width-4*mat,cross4[1]);
    translate([2*mat,depth/2+mat/2,cross5[0]])rotate([90,0,0])crosspanel(width-4*mat,cross5[1]);
    translate([2*mat,depth/2+mat/2,cross6[0]])rotate([90,0,0])crosspanel(width-4*mat,cross6[1]);
}
module flat(){
    translate([20,20,0])bottomplate(width,depth,400,150,corner);
    translate([40,670,0])sidepanel(depth,height,180,180,corner); 
    translate([1320,1020,0])rotate([0,0,180])sidepanel(depth,height,180,180,corner); 
    translate([1540,440,0])rotate([0,0,90])crosspanel(width-4*mat,cross1[1]);
    translate([900,20,0])crosspanel(width-4*mat,cross2[1]);
    translate([1680,440,0])rotate([0,0,90])crosspanel(width-4*mat,cross3[1]);
    translate([900,160,0])crosspanel(width-4*mat,cross4[1]);
    translate([400,1080,0])crosspanel(width-4*mat,cross5[1]);
    translate([900,280,0])crosspanel(width-4*mat,cross6[1]);
}
module bottomplate(bottom_width,bottom_depth,bottom_middlewidth,bottom_sidewidth,bottom_r) {
    difference(){
        union(){
            hull(){
                translate([bottom_r,bottom_r,0])cylinder(r=bottom_r,h=mat);
                translate([bottom_r,bottom_depth-bottom_r,0])cylinder(r=bottom_r,h=mat);
                translate([bottom_sidewidth-bottom_r,bottom_r,0])cylinder(r=bottom_r,h=mat);
                translate([bottom_sidewidth-bottom_r,bottom_depth-bottom_r,0])cylinder(r=bottom_r,h=mat);
            }
            hull(){
                translate([bottom_sidewidth-bottom_r,bottom_r,0])cylinder(r=bottom_r,h=mat);
                translate([bottom_sidewidth-bottom_r,bottom_depth-bottom_r,0])cylinder(r=bottom_r,h=mat); 
                translate([bottom_width/3-bottom_r,bottom_r+bottom_depth/2-bottom_middlewidth/2,0])cylinder(r=bottom_r,h=mat);
                translate([bottom_width/3-bottom_r,bottom_depth/2+bottom_middlewidth/2-bottom_r,0])cylinder(r=bottom_r,h=mat);   
            }
            hull(){
                translate([bottom_width/3-bottom_r,bottom_r+bottom_depth/2-bottom_middlewidth/2,0])cylinder(r=bottom_r,h=mat);
                translate([bottom_width/3-bottom_r,bottom_depth/2+bottom_middlewidth/2-bottom_r,0])cylinder(r=bottom_r,h=mat);
                translate([bottom_width-bottom_width/3+bottom_r,bottom_r+bottom_depth/2-bottom_middlewidth/2,0])cylinder(r=bottom_r,h=mat);
                translate([bottom_width-bottom_width/3+bottom_r,bottom_depth/2+bottom_middlewidth/2-bottom_r,0])cylinder(r=bottom_r,h=mat);
            }
            hull(){
                translate([bottom_width-bottom_width/3+bottom_r,bottom_r+bottom_depth/2-bottom_middlewidth/2,0])cylinder(r=bottom_r,h=mat);
                translate([bottom_width-bottom_width/3+bottom_r,bottom_depth/2+bottom_middlewidth/2-bottom_r,0])cylinder(r=bottom_r,h=mat);
                translate([bottom_width-bottom_sidewidth+bottom_r,bottom_r,0])cylinder(r=bottom_r,h=mat);
                translate([bottom_width-bottom_sidewidth+bottom_r,bottom_depth-bottom_r,0])cylinder(r=bottom_r,h=mat);
            }
            hull(){
                translate([bottom_width-bottom_sidewidth+bottom_r,bottom_r,0])cylinder(r=bottom_r,h=mat);
                translate([bottom_width-bottom_sidewidth+bottom_r,bottom_depth-bottom_r,0])cylinder(r=bottom_r,h=mat);
                translate([bottom_width-bottom_r,bottom_r,0])cylinder(r=bottom_r,h=mat);
                translate([bottom_width-bottom_r,bottom_depth-bottom_r,0])cylinder(r=bottom_r,h=mat);
            }
        }
        bottom_cutshapes(bottom_width,bottom_depth);
    }
}
module bottom_cutshapes(bottom_width,bottom_depth){
    translate([mat,tabspacing[0],0])millslot(tab);
    translate([mat,tabspacing[1],0])millslot(tab);
    translate([mat,bottom_depth-tabspacing[1]-tab,0])millslot(tab);
    translate([mat,bottom_depth-tabspacing[0]-tab,0])millslot(tab);
    translate([bottom_width-2*mat,tabspacing[0],0])millslot(tab);
    translate([bottom_width-2*mat,tabspacing[1],0])millslot(tab);
    translate([bottom_width-2*mat,bottom_depth-tabspacing[1]-tab,0])millslot(tab);
t   ranslate([bottom_width-2*mat,bottom_depth-tabspacing[0]-tab,0])millslot(tab);
}
module millslot(width){
    union(){
        translate([0,mill/2,0])cylinder(d=mill,h=mat+0.01);
        translate([0,width-mill/2,0])cylinder(d=mill,h=mat+0.01);
        translate([mat,width-mill/2,0])cylinder(d=mill,h=mat+0.01);
        translate([mat,mill/2,0])cylinder(d=mill,h=mat+0.01);
        translate([0,0,0])cube([mat,width,mat+0.01]);
    }
}
module tab(width){
    difference(){
        union(){
            translate([0,0,0])cube([mat,width,mat]);
            hull(){
                translate([0,mat/2,0])cylinder(d=mat,h=mat);
                translate([0,width-mat/2,0])cylinder(d=mat,h=mat);
            }
        }
        translate([-(peg)/2,mat,0])cylinder(d=peg,h=mat+0.01);
        translate([-(peg)/2,width-mat,0])cylinder(d=peg,h=mat+0.01);
    }
}
module sidepanel(bottom_width,panel_height,bottom_height,central_width,bottom_r){
    difference(){
        union(){
            hull(){  
                translate([0,bottom_r/2,0])cube([bottom_height-bottom_r,bottom_width-bottom_r,mat]);
                translate([bottom_height-bottom_r,bottom_r/2+bottom_r,0])cylinder(r=bottom_r,h=mat);
                translate([bottom_height-bottom_r,bottom_width-bottom_r-bottom_r/2,0])cylinder(r=bottom_r,h=mat);
            }
            hull(){
                translate([bottom_height-bottom_r,bottom_r/2+bottom_r,0])cylinder(r=bottom_r,h=mat);
                translate([bottom_height-bottom_r,bottom_width-bottom_r-bottom_r/2,0])cylinder(r=bottom_r,h=mat);
                translate([2*bottom_height-bottom_r,bottom_width/2-central_width/2+bottom_r,0])cylinder(r=bottom_r,h=mat);
                translate([2*bottom_height-bottom_r,bottom_width/2+central_width/2-bottom_r,0])cylinder(r=bottom_r,h=mat);  
            }          
            hull(){
                translate([bottom_height-bottom_r,bottom_width/2-central_width/2+bottom_r,0])cylinder(r=bottom_r,h=mat);
                translate([bottom_height-bottom_r,bottom_width/2+central_width/2-bottom_r,0])cylinder(r=bottom_r,h=mat);
                translate([panel_height-bottom_r,bottom_width/2-central_width/2+bottom_r,0])cylinder(r=bottom_r,h=mat);
                translate([panel_height-bottom_r,bottom_width/2+central_width/2-bottom_r,0])cylinder(r=bottom_r,h=mat);
            }
            translate([-mat,tabspacing[0],0])tab(tab);
            translate([-mat,tabspacing[1],0])tab(tab);
            translate([-mat,bottom_width-tabspacing[1]-tab,0])tab(tab);
            translate([-mat,bottom_width-tabspacing[0]-tab,0])tab(tab);
        }
        translate([0,tabspacing[0]-mill/2,0])cylinder(d=mill,h=10+mat+0.01);
        translate([0,tab+tabspacing[0]+mill/2,0])cylinder(d=mill,h=10+mat+0.01);  
        translate([0,tabspacing[1]-mill/2,0])cylinder(d=mill,h=10+mat+0.01);
        translate([0,tab+tabspacing[1]+mill/2,0])cylinder(d=mill,h=10+mat+0.01);
        translate([0,bottom_width-tabspacing[1]+mill/2,0])cylinder(d=mill,h=10+mat+0.01);
        translate([0,bottom_width-tabspacing[1]-tab-mill/2,0])cylinder(d=mill,h=10+mat+0.01);
        translate([0,bottom_width-tabspacing[0]+mill/2,0])cylinder(d=mill,h=10+mat+0.01);
        translate([0,bottom_width-tabspacing[0]-tab-mill/2,0])cylinder(d=mill,h=10+mat+0.01);    
        sidepanel_cutshapes(bottom_width);
    }    
}
module sidepanel_cutshapes(bottom_width){
        translate([cross1[0]+cross1[1]/2-tab/2-mat,bottom_width/2+mat/2,0])rotate([0,0,-90])millslot(tab);
        translate([cross2[0]+cross2[1]/2-tab/2-mat,bottom_width/2+mat/2,0])rotate([0,0,-90])millslot(tab);
        translate([cross3[0]+cross3[1]/2-tab/2-mat,bottom_width/2+mat/2,0])rotate([0,0,-90])millslot(tab);
        translate([cross4[0]+cross4[1]/2-tab/2-mat,bottom_width/2+mat/2,0])rotate([0,0,-90])millslot(tab);
        translate([cross5[0]+cross5[1]/2-tab/2-mat,bottom_width/2+mat/2,0])rotate([0,0,-90])millslot(tab);
        translate([cross6[0]+cross6[1]/2-tab/2-mat,bottom_width/2+mat/2,0])rotate([0,0,-90])millslot(tab);
}
module crosspanel(width,height){
    difference(){
        union(){
        cube([width,height,mat]);
        translate([-mat,height/2-tab/2,0])tab(tab);
        translate([width+mat,height/2+tab/2,0])rotate([0,0,180])tab(tab);
        }
        translate([0,height/2-tab/2-mill/2,0])cylinder(d=mill,h=10+mat+0.01);
        translate([0,tab+height/2-tab/2+mill/2,0])cylinder(d=mill,h=10+mat+0.01);  
        translate([width,height/2-tab/2-mill/2,0])cylinder(d=mill,h=10+mat+0.01);
        translate([width,tab+height/2-tab/2+mill/2,0])cylinder(d=mill,h=10+mat+0.01); 

    }
}