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Feature/rotate air holes for printing #14

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Feature/rotate air holes for printing #14

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0ec230e
Add configurable case_thickness parameter
phraktyl Nov 18, 2025
cc0b405
Merge pull request #1 from phraktyl/feature/add-case-thickness-parameter
phraktyl Nov 18, 2025
2d21b67
Changed the local hole_diameter to a more descriptive global wire_dia…
phraktyl Nov 18, 2025
99c3564
Merge pull request #2 from phraktyl/feature/add-wire-diameter-parameter
phraktyl Nov 18, 2025
f6e9e76
Moved the zip_tie_hole_width to the top for easier user configuration.
phraktyl Nov 18, 2025
06ffe42
Merge pull request #3 from phraktyl/feature/add-zip-tie-width-parameter
phraktyl Nov 18, 2025
6e7ee36
Rotate air holes for easier 3D printing without bridges.
phraktyl Nov 18, 2025
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33 changes: 16 additions & 17 deletions 10InchRackGenerator.scad
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Original file line number Diff line number Diff line change
Expand Up @@ -6,6 +6,9 @@ switch_width = 135.0;
switch_depth = 135.0;
switch_height = 28.30;

case_thickness = 6; // Thickness of case walls
wire_diameter = 7; // Diameter of power wire holes
zip_tie_hole_width = 1.5; // Width of zip tie slots

front_wire_holes = false; // [true:Show front wire holes, false:Hide front wire holes]
air_holes = true; // [true:Show air holes, false:Hide air holes]
Expand All @@ -20,14 +23,13 @@ height = 44.45 * rack_height;
module switch_mount(switch_width, switch_height, switch_depth) {
//6 inch racks (mounts=152.4mm; rails=15.875mm; usable space=120.65mm)
//10 inch racks (mounts=254.0mm; rails=15.875mm; usable space=221.5mm)
chassis_width = min(switch_width + 12, (rack_width == 152.4) ? 120.65 : 221.5);
chassis_width = min(switch_width + (2 * case_thickness), (rack_width == 152.4) ? 120.65 : 221.5);
front_thickness = 3.0;
corner_radius = 4.0;
chassis_edge_radius = 2.0;
tolerance = 0.42;

zip_tie_hole_count = 8;
zip_tie_hole_width = 1.5;
zip_tie_hole_length = 5;
zip_tie_indent_depth = 2;
zip_tie_cutout_depth = 7;
Expand Down Expand Up @@ -75,7 +77,7 @@ module switch_mount(switch_width, switch_height, switch_depth) {
// Create the main body as a separate module
module main_body() {
side_margin = (rack_width - chassis_width) / 2;
chassis_height = switch_height + 12;
chassis_height = switch_height + (2 * case_thickness);
union() {
// Front panel
linear_extrude(height = front_thickness) {
Expand Down Expand Up @@ -156,18 +158,17 @@ module switch_mount(switch_width, switch_height, switch_depth) {
}
}

// Power wire cutouts: 5mm diameter holes at top and bottom rack hole positions
// Power wire cutouts: configurable diameter holes at top and bottom rack hole positions
module power_wire_cutouts() {
hole_spacing_x = switch_width; // match rack holes
hole_diameter = 7;
hole_left_x = (rack_width - hole_spacing_x) / 2 - (hole_diameter /5);
hole_right_x = (rack_width + hole_spacing_x) / 2 + (hole_diameter /5);
hole_left_x = (rack_width - hole_spacing_x) / 2 - (wire_diameter /5);
hole_right_x = (rack_width + hole_spacing_x) / 2 + (wire_diameter /5);
// Midplane of switch opening
mid_y = (height - switch_height) / 2 + switch_height / 2;
for (side_x = [hole_left_x, hole_right_x]) {
translate([side_x, mid_y, 0]) {
linear_extrude(height = chassis_depth_main) {
circle(d=hole_diameter);
circle(d=wire_diameter);
}
}
}
Expand All @@ -185,7 +186,7 @@ module switch_mount(switch_width, switch_height, switch_depth) {

// Zip tie indents (top and bottom)
x_pos = (rack_width - switch_width)/2;
chassis_height = switch_height + 12;
chassis_height = switch_height + (2 * case_thickness);
// Bottom indent
translate([x_pos, (height - chassis_height)/2, switch_depth]) {
cube([switch_width, zip_tie_indent_depth, zip_tie_cutout_depth]);
Expand Down Expand Up @@ -227,7 +228,7 @@ module switch_mount(switch_width, switch_height, switch_depth) {
if (x_cols > 0 && z_rows > 0) {
for (i = [0:x_cols-1]) {
for (j = [0:z_rows-1]) {
// Stagger every other COLUMN (i) instead of row (j) for vertical honeycomb pattern
// Stagger every other COLUMN (i) for vertical honeycomb pattern
z_offset = (i % 2 == 1) ? spacing_z/2 : 0;
x_pos = x_start + i * spacing_x;
z_pos = z_start + j * spacing_z + z_offset;
Expand All @@ -236,7 +237,7 @@ module switch_mount(switch_width, switch_height, switch_depth) {
if (z_pos + hole_d/2 <= cutout_center_z + switch_depth/2 - margin &&
z_pos - hole_d/2 >= cutout_center_z - switch_depth/2 + margin) {
translate([x_pos, height, z_pos]) {
rotate([90, 0, 0]) {
rotate([90, 30, 0]) {
cylinder(h = height, d = hole_d, $fn = 6);
}
}
Expand All @@ -247,7 +248,7 @@ module switch_mount(switch_width, switch_height, switch_depth) {

// SIDE FACE HOLES (X-axis through left and right sides)
// Calculate chassis dimensions
chassis_width = min(switch_width + 12, (rack_width == 152.4) ? 120.65 : 221.5);
chassis_width = min(switch_width + (2 * case_thickness), (rack_width == 152.4) ? 120.65 : 221.5);
side_margin = (rack_width - chassis_width) / 2;

// Calculate available space within switch height
Expand Down Expand Up @@ -275,7 +276,7 @@ module switch_mount(switch_width, switch_height, switch_depth) {

for (i = [0:y_cols-1]) {
for (j = [0:z_rows_side-1]) {
// Stagger every other COLUMN (i) instead of row (j) for vertical honeycomb pattern
// Stagger every other COLUMN (i) for vertical honeycomb pattern
z_offset = (i % 2 == 1) ? spacing_z/2 : 0;
y_pos = y_start + i * spacing_x;
z_pos = z_start_side + j * spacing_z + z_offset;
Expand All @@ -285,9 +286,7 @@ module switch_mount(switch_width, switch_height, switch_depth) {
z_pos - hole_d/2 >= cutout_center_z - switch_depth/2 + margin) {
translate([side_x, y_pos, z_pos]) {
rotate([0, 90, 0]) {
rotate([0, 0, 90]) { // Rotate hexagon 90 degrees to match front/back orientation
cylinder(h = chassis_width, d = hole_d, $fn = 6);
}
cylinder(h = chassis_width, d = hole_d, $fn = 6);
}
}
}
Expand Down Expand Up @@ -323,4 +322,4 @@ if (print_orientation) {
rotate([-90,0,0])
translate([0, -height/2, -switch_depth/2])
switch_mount(switch_width, switch_height, switch_depth);
}
}