WLED_Billboard/LED Enclosure.scad

// -----------------------------------------------------------------------
// Modular 6-Part Enclosure for 10mm Pitch LED Matrix WITH DOVETAILS
// -----------------------------------------------------------------------
// NATIVE LANDSCAPE LAYOUT (3 columns x 2 rows)
// Select which tile to generate:
// 1 = Top Left      |  2 = Top Mid      |  3 = Top Right
// 4 = Bottom Left   |  5 = Bottom Mid   |  6 = Bottom Right
part = 1; // [1:6]

// --- Core Math ---
cellsX = 16; 
cellsY = 16; 
pitch = 10;
gridWidth = cellsX * pitch;
gridHeight = cellsY * pitch;
borderWidth = 10;

// Internal depth is 51mm (clearing the 49mm box height)
depth = 55; 
wall = 4;

// Logic for 3x2 Landscape Grid
hasLeft   = (part == 1 || part == 4) ? 1 : 0;
hasRight  = (part == 3 || part == 6) ? 1 : 0;
hasTop    = (part == 1 || part == 2 || part == 3) ? 1 : 0;
hasBottom = (part == 4 || part == 5 || part == 6) ? 1 : 0;

leftOffset = hasLeft * borderWidth;
bottomOffset = hasBottom * borderWidth;

totalWidth = gridWidth + (hasLeft * borderWidth) + (hasRight * borderWidth);
totalHeight = gridHeight + (hasTop * borderWidth) + (hasBottom * borderWidth);

$fn = 24;

// --- Dovetail Joint Geometry ---
module dovetail(clearance=0) {
    linear_extrude(wall)
    polygon([
        [-0.1, -6 - clearance],
        [8, -10 - clearance],
        [8, 10 + clearance],
        [-0.1, 6 + clearance]
    ]);
}

module posts() {
    holeRad = 1.4; // Sized for M3 self-tapping screws
    postRad = 4;
    
    // Left Border
    if (hasLeft) {
        for (i = [1 : 3]) {
            translate([borderWidth / 2, bottomOffset + (i * gridHeight/4), 0])
            difference() {
                cylinder(h=depth, r=postRad);
                translate([0, 0, wall]) cylinder(h=depth, r=holeRad);
            }
        }
    }
    // Right Border
    if (hasRight) {
        for (i = [1 : 3]) {
            translate([totalWidth - (borderWidth / 2), bottomOffset + (i * gridHeight/4), 0])
            difference() {
                cylinder(h=depth, r=postRad);
                translate([0, 0, wall]) cylinder(h=depth, r=holeRad);
            }
        }
    }
    // Top Border
    if (hasTop) {
        for (i = [1 : 3]) {
            translate([leftOffset + (i * gridWidth/4), totalHeight - (borderWidth / 2), 0])
            difference() {
                cylinder(h=depth, r=postRad);
                translate([0, 0, wall]) cylinder(h=depth, r=holeRad);
            }
        }
    }
    // Bottom Border
    if (hasBottom) {
        for (i = [1 : 3]) {
            translate([leftOffset + (i * gridWidth/4), borderWidth / 2, 0])
            difference() {
                cylinder(h=depth, r=postRad);
                translate([0, 0, wall]) cylinder(h=depth, r=holeRad);
            }
        }
    }
}

module keyhole() {
    cylinder(r=4, h=wall+2, center=true);
    translate([0, 6, 0]) cylinder(r=2.2, h=wall+2, center=true);
    translate([0, 3, 0]) cube([4.4, 6, wall+2], center=true);
}

difference() {
    union() {
        // Main block
        cube([totalWidth, totalHeight, depth]);
        
        // Add Male Dovetail Tabs on internal edges
        if (!hasRight) {
            for(i=[1:3]) translate([totalWidth, totalHeight * 0.25 * i, 0]) dovetail(0);
        }
        if (!hasBottom) {
            for(i=[1:3]) translate([totalWidth * 0.25 * i, 0, 0]) rotate([0, 0, -90]) dovetail(0);
        }
    }
    
    // Cavity cutout
    cutX = hasLeft ? wall : -1;
    cutY = hasBottom ? wall : -1;
    cutW = totalWidth - (hasLeft ? wall : -1) - (hasRight ? wall : -1);
    cutH = totalHeight - (hasBottom ? wall : -1) - (hasTop ? wall : -1);
    
    translate([cutX, cutY, wall])
    cube([cutW, cutH, depth]);
    
    // Subtract Female Dovetail Cuts on internal edges
    if (!hasLeft) {
        for(i=[1:3]) translate([0, totalHeight * 0.25 * i, 0]) dovetail(0.3);
    }
    if (!hasTop) {
        for(i=[1:3]) translate([totalWidth * 0.25 * i, totalHeight, 0]) rotate([0, 0, -90]) dovetail(0.3);
    }
    
    // Power Jack (9mm hole) straight through the right wall
    if (part == 6) {
        // Y = 17.5 (slot start) + 12.5 (center of 25mm controller) = 30
        // Z = 4 (floor) + 19 = 23
        translate([totalWidth + 1, 30, 23])
        rotate([0, -90, 0])
        cylinder(h=wall + 20, r=4.5);
    }
    
    // Wall mount keyholes on top parts 
    if (hasTop && hasLeft) {
        translate([totalWidth/2, totalHeight/2, wall/2])
        keyhole();
    }
    if (hasTop && hasRight) {
        translate([totalWidth/2, totalHeight/2, wall/2])
        keyhole();
    }
}

// Add mounting posts back into the cavity
posts();

// =================================================================
// PERPENDICULAR CONTROLLER SLOT
// Exclusively generated on Part 6. 
// Mounts the 25x49 face dead flush against the internal right wall.
// Controller extends 90mm inward along the X-axis.
// =================================================================
if (part == 6) {
    // Left retaining wall (X-axis inner stop at 90mm length)
    translate([73, 15.5, wall])
    cube([2, 30, 20]);
    
    // Top retaining wall (Y-axis upper stop)
    translate([73, 43.5, wall])
    cube([93, 2, 20]);
    
    // Bottom retaining wall (Y-axis lower stop)
    translate([73, 15.5, wall])
    cube([93, 2, 20]);
}