WLED_Billboard/LED Front grid.scad

// -----------------------------------------------------------------------
// Modular 10mm Pitch LED Matrix Grid WITH BORDER-ONLY BLIND SNAPS
// -----------------------------------------------------------------------
// 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]

// --- Matrix Parameters ---
cellsX = 16; 
cellsY = 16; 
pitch = 10; 
meshSolid = 2; 
meshSpace = pitch - meshSolid; // 8mm hole
thickness = 5; 

// --- Frame Parameters ---
borderWidth = 10; 
holeRad = 2; 

// --- Logic (Do not touch) ---
// FIXED: Mapped to 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; 

gridWidth = cellsX * pitch; 
gridHeight = cellsY * pitch; 

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

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

$fn = 16; 

// --- Border Insert Geometry (FDM friendly tapered hexagonal pegs) ---
module tab_x() {
    rotate([0, 90, 0]) rotate([0, 0, 30])
    cylinder(h=5, r1=1.8, r2=1.3, $fn=6);
}
module hole_x() {
    translate([-0.1, 0, 0])
    rotate([0, 90, 0]) rotate([0, 0, 30])
    cylinder(h=5.5, r1=2.0, r2=1.5, $fn=6);
}
module tab_y() {
    rotate([-90, 0, 0]) rotate([0, 0, 30])
    cylinder(h=5, r1=1.8, r2=1.3, $fn=6);
}
module hole_y() {
    translate([0, -0.1, 0])
    rotate([-90, 0, 0]) rotate([0, 0, 30])
    cylinder(h=5.5, r1=2.0, r2=1.5, $fn=6);
}

difference() {
    union() {
        // Base solid plate
        cube([totalWidth, totalHeight, thickness], center=false); 
        
        // Add Male pegs ONLY on the thick outer borders
        if (!hasRight) {
            if (hasTop) {
                translate([totalWidth, totalHeight - borderWidth/2, thickness/2]) tab_x();
            }
            if (hasBottom) {
                translate([totalWidth, borderWidth/2, thickness/2]) tab_x();
            }
        }
        if (!hasTop) {
            if (hasLeft) {
                translate([borderWidth/2, totalHeight, thickness/2]) tab_y();
            }
            if (hasRight) {
                translate([totalWidth - borderWidth/2, totalHeight, thickness/2]) tab_y();
            }
        }
    }
    
    // Punch out the LED cells
    for (x = [0 : cellsX - 1]) { 
        for (y = [0 : cellsY - 1]) { 
            translate([ 
                leftOffset + (meshSolid/2) + (x * pitch), 
                bottomOffset + (meshSolid/2) + (y * pitch), 
                -1 
            ]) 
            cube([meshSpace, meshSpace, thickness + 2], center=false); 
        } 
    } 

    // Cut Female holes ONLY on the thick outer borders
    if (!hasLeft) {
        if (hasTop) {
            translate([0, totalHeight - borderWidth/2, thickness/2]) hole_x();
        }
        if (hasBottom) {
            translate([0, borderWidth/2, thickness/2]) hole_x();
        }
    }
    if (!hasBottom) {
        if (hasLeft) {
            translate([borderWidth/2, 0, thickness/2]) hole_y();
        }
        if (hasRight) {
            translate([totalWidth - borderWidth/2, 0, thickness/2]) hole_y();
        }
    }

    // --- Mounting Holes ---
    // Left Border
    if (hasLeft) { 
        for (i = [1 : 3]) { 
            translate([borderWidth / 2, bottomOffset + (i * gridHeight/4), -1]) 
            cylinder(h=thickness + 2, r=holeRad); 
        } 
    } 
    
    // Right Border
    if (hasRight) { 
        for (i = [1 : 3]) { 
            translate([totalWidth - (borderWidth / 2), bottomOffset + (i * gridHeight/4), -1]) 
            cylinder(h=thickness + 2, r=holeRad); 
        } 
    } 

    // Top Border
    if (hasTop) { 
        for (i = [1 : 3]) { 
            translate([leftOffset + (i * gridWidth/4), totalHeight - (borderWidth / 2), -1]) 
            cylinder(h=thickness + 2, r=holeRad); 
        } 
    } 

    // Bottom Border
    if (hasBottom) { 
        for (i = [1 : 3]) { 
            translate([leftOffset + (i * gridWidth/4), borderWidth / 2, -1]) 
            cylinder(h=thickness + 2, r=holeRad); 
        } 
    } 
}