//-----------------------------------------------------------------------
// 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 = [
  [22, 10, 0, 0, 0.5*25.4/2, yappCircle],
  [2, 35, 0, 0, 0.5*25.4/2, yappCircle],
];

snapJoins = [
  [10,5,yappFront,yappBack,yappSymmetric]
];

//---------------------------------------------------------------
// 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();
}

//---------------------------------------------------------------
// Skull faceplate / grille
//   A round faceplate, raised proud of the front face, that fully
//   overlaps the 45mm speaker opening and fuses to the solid front
//   wall around it. A skull face is cut through it as the speaker
//   grille - eye sockets and nasal opening come straight from the
//   icon, plus a row of added tooth slots in the jaw.
//   skull.svg: "death-skull" by sbed / game-icons.net - CC BY 3.0
//   https://game-icons.net/1x1/sbed/death-skull.html
//---------------------------------------------------------------
plateDia      = 50;    // faceplate diameter (> 45mm opening -> fused rim)
plateRaise    = 1;   // mm proud of the front face
plateEmbed    = 5;   // mm the plate sinks into the front wall (weld)
skullFaceW    = 46;    // skull width across the plate
skullMaskD    = 44;    // opened-up disc around the skull -> the grille voids
frontOuterX   = shellInsideLength + 2*wallThickness;  // X of the outer front face
speakerYc     = 27;    // speaker opening centre (Y)
speakerZc     = 28.6;  // speaker opening centre (Z)

// skull.svg imports at ~180.6mm wide (512-unit viewBox at 72dpi)
skullImportW  = 180.6;

module skullArt() { import("skull-2.svg", center = true); }

// The faceplate is a solid disc. The grille is the skull's negative
// space: inside a centre disc, everything that is NOT skull bone is
// opened up - eye sockets, nasal opening and the crescent gaps around
// the cranium and jaw. The bone itself stays as plate material, so the
// disc is never cut through and the skull reads by its voids.
module grille2D()
{
  difference()
  {
    circle(d = plateDia, $fn = 160);
    difference()
    {
      circle(d = skullMaskD, $fn = 150);
      scale(skullFaceW / skullImportW) skullArt();
    }
    // teeth: a row of slots cut into the jaw for extra grille area
    //for (i = [-2 : 2])
      //translate([i * 4.4, -15.5]) square([2.2, 7], center = true);
  }
}

module skullFaceplate()
{
  // hookBaseOutside() shares the inner-corner origin:
  //   global = hookCoord + [wallThickness, wallThickness, basePlaneThickness]
  translate([-wallThickness, -wallThickness, -basePlaneThickness])
    translate([frontOuterX - plateEmbed, speakerYc, speakerZc])
      rotate([90, 0, 90])            // 2D x->Y, 2D y->Z, extrude->+X
        linear_extrude(plateRaise + plateEmbed)
          grille2D();
}

module hookBaseOutside()
{
  skullFaceplate();
}

showOrientation = true;
YAPPgenerate();