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 back plane is flat
// against the wall but its top corners are rounded, and that rounding blends
// through to the spherical front corners so nothing tapers to a point. One
// radius for all rounding, sharp bottom edge. 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 in mm.
total_width = 500; // [300:10:800]
// Height of the front fascia in mm.
height = 100; // [70:5:140]
// Depth from the wall in mm.
depth = 100; // [70:5:140]

/* [Rounding] */
// One radius for all rounded edges: the top front edge, the vertical front edges, the corner blends and the top corners of the back outline. The back plane always stays flat against the wall and the bottom edge always stays sharp.
rounding = 14; // [2:1:40]

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

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

/* [GU10 socket, measure yours] */
// Centre distance of the two fixing holes of your GU10 socket.
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;
r_ = min(rounding, height / 2 - 2, depth / 2 - 2, total_width / 4);
r_i = max(r_ - wall, 1);
function sx(i) = (i + 0.5) * total_width / spots;

// ---- Shell: flat back with rounded top corners, rounded front, sharp bottom ----

// A rectangle in the wall plane with rounded top corners.
module back_face_2d(x0, x1, z0, z1, r)
  hull() {
    translate([x0, z0]) square([x1 - x0, max(z1 - z0 - r, 0.1)]);
    translate([x0 + r, z1 - r]) circle(r);
    translate([x1 - r, z1 - r]) circle(r);
  }

module bar_solid()
  hull() {
    translate([0, 1, 0]) rotate([90, 0, 0])
      linear_extrude(1) back_face_2d(0, total_width, 0, height, r_);
    for (px = [r_, total_width - r_]) {
      translate([px, depth - r_, 0]) cylinder(r = r_, h = 1);
      translate([px, depth - r_, height - r_]) sphere(r = r_);
    }
    translate([r_, depth - r_, height - r_])
      rotate([0, 90, 0]) cylinder(r = r_, h = total_width - 2 * r_);
  }

module cavity()
  hull() {
    translate([0, wall + 1, 0]) rotate([90, 0, 0])
      linear_extrude(1)
        back_face_2d(wall, total_width - wall, plate_top, height - wall, r_i);
    for (px = [wall + r_i, total_width - wall - r_i]) {
      translate([px, depth - wall - r_i, plate_top]) cylinder(r = r_i, h = 1);
      translate([px, depth - wall - r_i, height - wall - r_i]) sphere(r = r_i);
    }
    translate([wall + r_i, depth - wall - r_i, height - wall - r_i])
      rotate([0, 90, 0]) cylinder(r = r_i, h = total_width - 2 * (wall + r_i));
  }

// Bottom opening: the plan outline inset by one wall, front corners following the rounding.
module plan_in()
  hull() {
    translate([wall, wall]) square([total_width - 2 * wall, 1]);
    for (px = [wall + r_i, total_width - wall - r_i])
      translate([px, depth - wall - r_i]) circle(r = r_i);
  }

module trough()
  translate([0, 0, -1]) linear_extrude(lip + 1) plan_in();

// ---- 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();
}