Speaker box: add angled speaker-retaining rib with flared foot

speakerbox.scad

@@ -0,0 +1,107 @@
+//-----------------------------------------------------------------------
+// Speaker enclosure - 4cm x 5cm x 10cm exterior, 4.5cm speaker opening
+// Built with YAPP_Box (YAPPgenerator_v3.scad)
+//-----------------------------------------------------------------------
+include <./YAPPgenerator_v3.scad>
+
+printBaseShell = true;
+printLidShell  = true;
+
+// Reference "PCB" - there's no real PCB here, this block just defines
+// the box's internal footprint. Exterior = pcbLength/pcbWidth + 2*wallThickness
+// (padding = 0), so: 36 + 2*2 = 40mm, 46 + 2*2 = 50mm.
+pcbLength           = 40;   // X axis (front-to-back) -> 4cm exterior
+pcbWidth            = 50;   // Y axis (side-to-side)  -> 5cm exterior
+pcbThickness        = 1.6;
+standoffHeight      = 0;
+standoffDiameter    = 0;
+standoffPinDiameter = 0;
+
+pcb = [
+  ["Main", pcbLength, pcbWidth, 0, 0, pcbThickness,
+   standoffHeight, standoffDiameter, standoffPinDiameter, 0.4]
+];
+
+paddingFront = 0;
+paddingBack  = 0;
+paddingRight = 0;
+paddingLeft  = 0;
+
+wallThickness      = 2.0;
+basePlaneThickness = 2.0;
+lidPlaneThickness  = 2.0;
+
+// Total exterior height = basePlaneThickness + baseWallHeight
+//                        + lidWallHeight + lidPlaneThickness
+//                        = 2 + 86 + 10 + 2 = 100mm (10cm)
+baseWallHeight = 86;
+lidWallHeight  = 10;
+
+ridgeHeight = 5.0;
+roundRadius = 3.0;
+
+//---------------------------------------------------------------
+// Speaker cutout - centered on the Front face (the 5cm x 10cm face)
+// Front face local coords (yappCoordBox, corner-referenced):
+//   p(0) = position from the Left edge (Y axis)
+//   p(1) = position from the Bottom edge (Z axis)
+// A 45mm circle centered at Y=25, Z=50 has its bounding-box corner at:
+//   p1 = 50 - 22.5 = 27.5
+//---------------------------------------------------------------
+cutoutsFront = [
+  [2.5, 2.5, 0, 0, 22.5, yappCircle]
+];
+
+cutoutsLid = [
+  [7, 14, 0, 0, 0.25*25.4, yappCircle],
+  [25, 35, 0, 0, 0.125*25.4, yappCircle],
+];
+
+//---------------------------------------------------------------
+// Angled speaker-retaining wall
+//   A near-vertical rib that rises 30mm from the front-bottom of
+//   the base and leans slightly back toward the box centre. Its
+//   speaker-facing surface sits 15mm behind the front (speaker)
+//   wall at the floor and 17.5mm behind it at the top, so it
+//   backstops the speaker and holds it against the speaker hole.
+//---------------------------------------------------------------
+frontInnerX   = shellInsideLength + wallThickness;  // X of inner front-wall face
+retainGapBot  = 15;    // mm behind the front wall at the floor
+retainGapTop  = 17.5;  // mm behind the front wall at the top
+retainHeight  = 30;    // rib height above the base floor
+retainThick   = 2.4;   // rib wall thickness
+retainWidth   = 40;    // Y span (a little wider than the speaker)
+retainYc      = 27;    // Y centre (matches the speaker cutout)
+retainFoot    = 10;    // how far the base flares back toward centre
+retainFootH   = 14;    // height over which the flare tapers back in
+
+module speakerRetainer()
+{
+  xBot = frontInnerX - retainGapBot;
+  xTop = frontInnerX - retainGapTop;
+  zBot = basePlaneThickness;
+  zTop = basePlaneThickness + retainHeight;
+
+  // hookBaseInside() origin sits at the inner corner:
+  //   global = hookCoord + [wallThickness, wallThickness, basePlaneThickness]
+  // X grows toward the speaker hole; the flared foot extends the other
+  // way (toward box centre) so it never touches the speaker. Each layer
+  // sits fully on the one below it, so it prints without support.
+  translate([-wallThickness, -wallThickness, -basePlaneThickness])
+    translate([0, retainYc + retainWidth/2, 0])
+      rotate([90, 0, 0])
+        linear_extrude(height = retainWidth)
+          polygon([[xBot + retainThick, zBot],                  // front face, floor
+                   [xBot - retainFoot,  zBot],                  // flared foot toe
+                   [xTop,               zBot + retainFootH],    // foot tapers into back face
+                   [xTop,               zTop],                  // back face, top
+                   [xTop + retainThick, zTop]]);                // front face, top
+}
+
+module hookBaseInside()
+{
+  speakerRetainer();
+}
+
+showOrientation = true;
+YAPPgenerate();