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