Bathroom mirror light bar

// Bathroom mirror light bar. Remix of mick/lamp-fittings: the GU10 holder cups
// from that model are built into a wall mounted bar. Spots point down behind a
// front lip, so the lamps are hidden from the front. The shell is rounded on the
// top edge, bottom edge and vertical end edges, flat against the wall at the back.
// Split into segments that fit a small printer bed and join on 4 mm dowels.

/* [Model] */
// The whole bar, or one print segment laid flat.
part = "all"; // [all, segment]
// Which segment when part = segment.
segment_index = 1; // [1:1:6]
// Slice the display view open through the spots.
cutaway = false;

/* [Size] */
// Width of the bar.
total_width = 500; // [300:10:800]
// Height of the front fascia.
height = 100; // [70:5:140]
// Depth from the wall.
depth = 100; // [70:5:140]

/* [Rounding] */
// Rounding of the top front edge.
r_top = 18; // [4:1:30]
// Rounding of the bottom front edge.
r_bottom = 6; // [0:1:12]
// Rounding of the vertical end edges.
r_side = 10; // [2:1:20]

/* [Light] */
// Number of GU10 spots.
spots = 3; // [2:1:5]
// How far the fascia drops past the lamp faces.
lip = 15; // [8:1:30]

/* [Build] */
// Number of print segments. Keep total_width / segments under your bed size.
segments = 3; // [1:1:6]
// Wall thickness.
wall = 2.5; // [2:0.25:4]
// Thickness of the bottom plate.
plate_t = 3; // [2:0.5:5]

/* [GU10 socket, measure yours] */
// Centre distance of the socket fixing holes.
gu10_hole_span = 40; // [24:1:50]

/* [Quality] */
// Facets on round surfaces.
smoothness = 96; // [24:8:160]

/* [Colour] */
// Display colour of the body.
color_body = "White"; // [White, Silver, Gainsboro, DimGray, Black, SlateGray, FireBrick, SteelBlue, ForestGreen, Goldenrod]

/* [Hidden] */
$fn = smoothness;
eps = 0.01;
clearance = 0.3;
spot_len = 46;                 // GU10 lamp length without pins
cup_id = 50 + 2 * clearance;   // bore for the 50 mm lamp face
cup_od = cup_id + 2 * wall;
plate_bot = lip;
plate_top = lip + plate_t;
cap_bot = lip + spot_len;      // lamp sits flush with the plate underside
seg_w = total_width / segments;
rt_ = min(r_top, height / 2 - 2, depth / 2 - 2);
rb_ = max(min(r_bottom, depth / 4), 0.3);
rs_ = min(r_side, total_width / 4, depth / 2 - 2);
rt_i = max(rt_ - wall, 1);
rs_i = max(rs_ - wall, 1);
function sx(i) = (i + 0.5) * total_width / spots;

// ---- Shell profiles: back edge square in all three views ----

// Side view (u = depth, v = height): top and bottom front rounding.
module prof_yz()
  hull() {
    translate([depth - rt_, height - rt_]) circle(r = rt_);
    translate([depth - rb_, rb_]) circle(r = rb_);
    square([1, height]);
  }

module prof_yz_in()
  hull() {
    translate([depth - wall - rt_i, height - wall - rt_i]) circle(r = rt_i);
    translate([wall, plate_top]) square([1, height - wall - plate_top]);
    translate([depth - wall - 1, plate_top]) square(1);
  }

// Top view (u = width, v = depth): vertical end edge rounding.
module prof_xy()
  hull() {
    for (px = [rs_, total_width - rs_])
      translate([px, depth - rs_]) circle(r = rs_);
    square([total_width, 1]);
  }

module prof_xy_in()
  hull() {
    for (px = [wall + rs_i, total_width - wall - rs_i])
      translate([px, depth - wall - rs_i]) circle(r = rs_i);
    translate([wall, wall]) square([total_width - 2 * wall, 1]);
  }

// End view (u = width, v = height): soften the top end corners.
module prof_xz()
  hull() {
    for (px = [rs_, total_width - rs_])
      translate([px, height - rs_]) circle(r = rs_);
    square([total_width, 1]);
  }

module prof_xz_in()
  hull() {
    for (px = [wall + rs_i, total_width - wall - rs_i])
      translate([px, height - wall - rs_i]) circle(r = rs_i);
    translate([wall, wall]) square([total_width - 2 * wall, 1]);
  }

module bar_solid()
  intersection() {
    rotate([90, 0, 90]) linear_extrude(total_width) prof_yz();
    linear_extrude(height) prof_xy();
    translate([0, depth, 0]) rotate([90, 0, 0]) linear_extrude(depth) prof_xz();
  }

module cavity()
  intersection() {
    rotate([90, 0, 90]) linear_extrude(total_width) prof_yz_in();
    linear_extrude(height) prof_xy_in();
    translate([0, depth, 0]) rotate([90, 0, 0]) linear_extrude(depth) prof_xz_in();
  }

module trough()
  translate([wall + rs_, wall, -1])
    cube([total_width - 2 * (wall + rs_), depth - 2 * wall - rb_, lip + 1]);

// ---- Spot cups (construction from mick/lamp-fittings) ----

module cups()
  for (i = [0:spots - 1])
    translate([sx(i), depth / 2, plate_bot])
      cylinder(d = cup_od, h = spot_len + plate_t);

module cup_bores()
  for (i = [0:spots - 1])
    translate([sx(i), depth / 2, -1])
      cylinder(d = cup_id, h = cap_bot + 1);

module cap_holes()
  for (i = [0:spots - 1])
    translate([sx(i), depth / 2, cap_bot - 1]) {
      cylinder(d = 30, h = plate_t + 2);
      for (s = [-1, 1])
        translate([s * gu10_hole_span / 2, 0, 0])
          cylinder(d = 2.8, h = plate_t + 2);
    }

// ---- Segment joints ----

module join_blocks()
  if (segments > 1)
    for (j = [1:segments - 1]) {
      xi = j * seg_w;
      translate([xi - 12, wall, plate_top]) cube([24, 12, 12]);
      translate([xi - 12, depth - wall - 12, plate_top]) cube([24, 12, 12]);
      translate([xi - 12, depth / 2 - 6, height - wall - 12]) cube([24, 12, 12]);
    }

module dowel_holes()
  if (segments > 1)
    for (j = [1:segments - 1]) {
      xi = j * seg_w;
      for (p = [[wall + 6, plate_top + 6],
                [depth - wall - 6, plate_top + 6],
                [depth / 2, height - wall - 6]])
        translate([xi, p[0], p[1]])
          rotate([0, 90, 0])
            cylinder(d = 4.2, h = 24, center = true);
    }

// ---- Wall mount and cable ----

module keyholes()
  for (kx = [0.18 * total_width, 0.82 * total_width])
    translate([kx, -1, 0]) rotate([-90, 0, 0]) {
      translate([0, -(height - 35), 0]) cylinder(d = 9, h = wall + 2);
      hull()
        for (dz = [0, 12])
          translate([0, -(height - 35) - dz, 0])
            cylinder(d = 4.5, h = wall + 2);
    }

module cable_hole()
  translate([total_width / 2, -1, height - 25])
    rotate([-90, 0, 0])
      cylinder(d = 8, h = wall + 2);

// ---- Body ----

module body()
  difference() {
    union() {
      difference() {
        bar_solid();
        cavity();
        trough();
      }
      intersection() {
        union() {
          cups();
          join_blocks();
        }
        bar_solid();
      }
    }
    cup_bores();
    cap_holes();
    dowel_holes();
    keyholes();
    cable_hole();
  }

module spot_mock()
  color("Gainsboro") {
    cylinder(d = 50, h = 6);
    translate([0, 0, 6]) cylinder(d1 = 50, d2 = 24, h = 32);
    translate([0, 0, 38]) cylinder(d = 24, h = 8);
  }

module display() {
  color(color_body) body();
  for (i = [0:spots - 1])
    translate([sx(i), depth / 2, plate_bot]) spot_mock();
}

// ---- Layout ----

if (part == "segment") {
  si = min(segment_index, segments);
  rotate([90, 0, 0])
    translate([-(si - 1) * seg_w, 0, 0])
      intersection() {
        color(color_body) body();
        translate([(si - 1) * seg_w, -10, -10])
          cube([seg_w, depth + 20, height + 20]);
      }
} else {
  if (cutaway)
    difference() {
      display();
      translate([-10, -10, -10])
        cube([total_width + 20, depth / 2 + 10, height + 20]);
    }
  else
    display();
}