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. Optional tilting: each spot becomes a cartridge pivoting fore and
// aft on 1.75 mm filament hinge pins in a ring on the bottom plate, with a
// countersunk pocket at each ring hole to secure the pin with glue or a melted
// mushroom head. Flat back with rounded top corners blending into spherical
// front corners, sharp bottom edge, service windows behind the spots. Split
// into printer bed sized segments joined on 4 mm dowels.

/* [Model] */
// The whole bar, one print segment laid flat, or one tilt cartridge print ready.
part = "all"; // [all, segment, cartridge]
// 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]
// Thickness of the visible rim around the bottom opening.
rim = 2.5; // [2:0.5:12]

/* [Tilting] */
// Make the spots tiltable: each spot becomes a cartridge that pivots forward and back on 1.75 mm filament hinge pins. Print one cartridge per spot with part = cartridge. Secure the pins in their pockets with CA glue or a melted end.
tilting = false;
// Designed tilt range in degrees to either side. The ring and plate opening are carved to clear this.
max_tilt = 15; // [5:1:20]
// Tilt of the cartridges in the preview only, degrees. Positive tilts forward.
tilt_angle = 0; // [-20:1:20]

/* [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 face 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);
r_rim = max(r_ - rim, 1);
spacing = total_width / spots;
win_w = max(spacing - 56, 40);       // service window width
win_z0 = plate_top + 4;              // service window bottom
win_z1 = height - 14;                // service window top
function sx(i) = (i + 0.5) * spacing;
kx1 = (sx(0) + sx(1)) / 2 - 12;
kx2 = (sx(spots - 2) + sx(spots - 1)) / 2 + 12;
// Tilting geometry
cart_od = cup_id + 2 * wall;         // cartridge outer diameter
cart_h = spot_len + plate_t;         // cartridge height including cap
pivot_rel = 15;                      // pivot above the lamp face
pivot_z = lip + pivot_rel;
gap_t = 1.5;                         // radial clearance cartridge to ring at the pivot
ring_wall = 2.5;
ring_od = cart_od + 2 * gap_t + 2 * ring_wall;
ring_top = pivot_z + 8;
tilt_show = max(-max_tilt, min(max_tilt, tilt_angle));

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

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));
  }

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

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

// ---- Service windows: one behind each spot, hidden by the wall ----

module rrect2(w, h, r)
  hull()
    for (dx = [r, w - r], dz = [r, h - r])
      translate([dx, dz]) circle(r);

module service_windows()
  for (i = [0:spots - 1])
    translate([sx(i) - win_w / 2, wall + 1, win_z0])
      rotate([90, 0, 0])
        linear_extrude(wall + 2)
          rrect2(win_w, win_z1 - win_z0, 6);

// ---- Fixed 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);
    }

// ---- Tilting: pivot rings, swept clearance and the cartridge ----

// The volume the cartridge sweeps between -max_tilt and +max_tilt, with clearance.
module cart_sweep()
  hull()
    for (a = [-max_tilt, 0, max_tilt])
      translate([0, 0, pivot_rel])
        rotate([a, 0, 0])
          translate([0, 0, -pivot_rel - 1])
            cylinder(d = cart_od + 2.4, h = cart_h + 2);

module rings()
  for (i = [0:spots - 1])
    translate([sx(i), depth / 2, plate_bot])
      cylinder(d = ring_od, h = ring_top - plate_bot);

module ring_carve()
  for (i = [0:spots - 1])
    translate([sx(i), depth / 2, plate_bot])
      cart_sweep();

module pivot_holes()
  for (i = [0:spots - 1])
    translate([sx(i), depth / 2, pivot_z]) {
      rotate([0, 90, 0])
        cylinder(d = 2.0, h = ring_od + 8, center = true);
      // Countersunk pockets on the ring outside: seat for CA glue or a melted pin head.
      for (s = [-1, 1])
        translate([s * (ring_od / 2 - 0.6), 0, 0])
          rotate([0, 90, 0])
            cylinder(d = 4.5, h = 1.4, center = true);
    }

// The tilt cartridge itself: the cup as a separate part with press fit pin holes.
module cartridge_part()
  difference() {
    cylinder(d = cart_od, h = cart_h);
    translate([0, 0, -1]) cylinder(d = cup_id, h = spot_len + 1);
    translate([0, 0, spot_len - 1]) cylinder(d = 30, h = plate_t + 2);
    for (s = [-1, 1])
      translate([s * gu10_hole_span / 2, 0, spot_len - 1])
        cylinder(d = 2.8, h = plate_t + 2);
    translate([0, 0, pivot_rel])
      rotate([0, 90, 0])
        cylinder(d = 1.7, h = cart_od + 2, center = true);
  }

// ---- 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 ----

module keyholes()
  for (kx = [kx1, kx2])
    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);
    }

// ---- Body ----

module body()
  difference() {
    union() {
      difference() {
        bar_solid();
        cavity();
        trough();
      }
      intersection() {
        union() {
          if (tilting) rings(); else cups();
          join_blocks();
        }
        bar_solid();
      }
    }
    if (tilting) {
      ring_carve();
      pivot_holes();
    } else {
      cup_bores();
      cap_holes();
    }
    dowel_holes();
    keyholes();
    service_windows();
  }

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])
      if (tilting) {
        translate([0, 0, pivot_rel])
          rotate([tilt_show, 0, 0])
            translate([0, 0, -pivot_rel]) {
              color(color_body) cartridge_part();
              spot_mock();
            }
      } else {
        spot_mock();
      }
}

// ---- Layout ----

if (part == "cartridge") {
  translate([0, 0, cart_h]) rotate([180, 0, 0])
    color(color_body) cartridge_part();
} else 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();
}