Tiny whoop case with drop-in trays, click jaws and a port slider

// Tiny whoop case: a whoop, its BetaFPV charger and a row of 1S batteries in one
// hinged box, printed in PETG, with a smooth outside. One shell for everything and
// two drop-in trays: a whoop tray with a pocket shaped around the ducts of one
// whoop, and a charger tray with two click jaws that ratchet against the charger.
// A flush slider opens and closes the charging window. The lid holds the batteries
// on their side in snap clips. Every part prints without supports.
//
// Coordinates: y = 0 at the rear (hinges), y = Sy at the front (latch). Seen from
// the front, the viewer's right is low x: the charger sits in the corner at low x,
// high y. The lid is modelled closed and flipped for printing.

/* [Part] */
// The whole case with the lid open, or one part in print orientation.
part = "assembly"; // [assembly, base, lid, whoop_tray, charger_tray, jaws, slider]
// Print a coupon set instead: one hinge and the latch in base and lid halves, the
// slider channel with the slider, a strip of charger tray with the side jaw, and
// one battery clip.
test_print = false;
// Show the whoop, the charger and the batteries as ghosts in the assembly.
show_contents = false;

/* [Whoop] */
// The whoop the whoop tray is for. Motor to motor across the diagonal: 80 for a
// Meteor75 Pro II, the largest the case takes.
whoop_wheelbase = 80; // [55:0.5:80]
// Outer diameter of one duct, up to 50.
duct_d = 50; // [28:0.5:50]
// Total height of the whoop, camera included: sets the height of the case.
whoop_h = 40; // [20:1:60]

/* [Charger] */
// Height of the charger: the jaw lips catch its top edge. 19 for the BetaFPV 6-port
// charger, 22 for the BT2.0 charger board.
charger_h = 19; // [14:0.5:24]
// Charging port: distance from the outer side of the charger to the middle of the
// port, and height of the middle of the port above the floor.
port_from_side = 23; // [10:0.5:40]
port_z = 9.5; // [6:0.5:20]

/* [Batteries] */
// LAVA size family: 480 to 680 mAh (15 mm wide), or 280 and 320 mAh (10 mm wide).
battery_class = "LAVA 480-680"; // [LAVA 480-680, LAVA 280-320]
// Batteries in the lid, standing on their side. 0 for an empty lid.
battery_count = 8; // [0:1:12]

/* [Colour] */
// Display only, the STL carries no colour.
color_case = "SteelBlue"; // [SteelBlue, White, DimGray, Black, FireBrick, Goldenrod, ForestGreen, MediumPurple]

/* [Hidden] */
$fn = 64;
wall = 3.2;
floor_t = 2;
top_t = 2;
corner_r = 6;
bot_ch = 1.5;
top_ch = 2;
seam_ch = 0.6;
// trays: clearance in the shell, whoop tray height, charger tray height, clearance
// around the whoop, the largest whoop the shell takes
t_clr = 0.3;
deck_h = 14;
ct_h = 12;
c_clr = 0.5;
max_wb = 80;
max_dd = 50;
// charger: the largest footprint the jaws open to, the ghost charger (BetaFPV
// 6-port), the length of the side and the rear jaw (their travel is 9 less)
ch_w = 46.5;
ch_l = 80.5;
gh_w = 46;
gh_l = 79;
l_side = 14;
l_rear = 19;
jaw_h = charger_h - ct_h + 3.6;
// port slider: width, height, thickness, travel, tongue centre from its left edge
sl_w = 26;
sl_h = 16;
sl_t = 1.6;
sl_travel = 13;
tg_x = sl_w / 2 + 9.5;
// lip on the base rim, recess in the lid
lip_h = 2;
lip_t = 1.2;
lip_c = 0.25;
// battery clips
big_bat = battery_class == "LAVA 480-680";
battery_w = big_bat ? 15.5 : 10.5;
battery_t = big_bat ? 7 : 6.5;
battery_l = big_bat ? 80 : 64;
bat_clr = 0.25;
arm_t = 1.4;
arm_w = 6;
arm_gap = 1.6;
bump = 0.7;
clip_y = 17;
// hinges: pin hole, knuckle radius, axis behind the rear face, segment width and gap
bolt_d = 3.4;
rk = 4;
hk = rk + 0.5;
seg_w = 8;
seg_gap = 0.4;
hinge_in = 22;
// latch
latch_w = 20;
latch_drop = 10;
tongue_t = 1.6;

sq = whoop_wheelbase / sqrt(2);
whoop_zone = max_wb / sqrt(2) + max_dd + 2 * c_clr + 2.4;
// charger zone across x: charger, side jaw groove, wall behind it
x_pw = wall + ch_w;
x_cz = x_pw + l_side + 0.5 + 1.5;
bat_pitch = battery_t + 2 * (bat_clr + arm_t) + arm_gap;
Sx_in = max(x_cz - wall + 2 * t_clr + whoop_zone, battery_count * bat_pitch + 8);
Sy_in = max(whoop_zone + 2 * t_clr, ch_l + l_rear + 0.5 + 1.5 + t_clr, battery_l + 12);
Sx = Sx_in + 2 * wall;
Sy = Sy_in + 2 * wall;
fz = floor_t;
cav_h = max(whoop_h + 2, charger_h + 6, deck_h + 4);
base_h = fz + cav_h;
zc = base_h;
lid_cav = max(battery_w + 2.5, 9);
lid_h = top_t + lid_cav;
pb = zc + lid_h - top_t;
// charger along y: front face on the front wall, rear jaw behind it
yf = Sy - wall;
y_pr = yf - ch_l;
y_ji = yf - 40;
x_jr = wall + ch_w / 2;
// whoop centre
dx = (x_cz + Sx - wall) / 2;
dy = Sy / 2;
// charging window and slider
px = max(corner_r + sl_w / 2 + sl_t + 1.5, min(wall + port_from_side, x_cz - sl_w / 2 - 3));
pz = fz + max(9.5, min(port_z, cav_h - 23));
sl_z0 = pz - sl_h / 2;

// ---- 2D helpers ----

module outer2d() {
  offset(r = corner_r) offset(delta = -corner_r) square([Sx, Sy]);
}

module inset2d(k) {
  offset(r = -k) outer2d();
}

module ring2d(a, b) {
  difference() { inset2d(a); inset2d(b); }
}

// Horizontal hole that prints without support: the tip points up in 2D y.
module teardrop2d(r) {
  circle(r = r);
  rotate(45) square(r);
}

// Whoop outline: four ducts on a square of side s, and the frame between them.
module whoop2d(s, d) {
  for (sx = [-1, 1], sy = [-1, 1]) translate([sx * s / 2, sy * s / 2]) circle(d = d);
  square(s, center = true);
}

// The charging window: 14 x 9 with chamfered top corners, so the top is an 8 mm
// bridge.
module win2d() {
  polygon([[-7, -4.5], [7, -4.5], [7, 1.5], [4, 4.5], [-4, 4.5], [-7, 1.5]]);
}

// ---- Hinge ----
// Knuckle profile in (y, z) about the hinge axis, which sits hk behind the rear face
// at rim height. Its underside runs into the wall at 45 degrees. The lid mirrors it
// about the rim, so both halves print without support.

module knuckle_profile() {
  difference() {
    hull() {
      translate([-hk, 0]) circle(r = rk);
      translate([-0.01, -hk - 1.42 * rk]) square([1, hk + 1.42 * rk - 2]);
    }
    translate([-hk, 0]) teardrop2d(bolt_d / 2);
  }
}

module knuckle2d(upper) {
  translate([0, zc]) {
    if (upper) mirror([0, 1]) knuckle_profile();
    else knuckle_profile();
  }
}

// Two hinges, each base-lid-base on one M3 x 30 bolt with a nut.
module knuckles(upper) {
  for (gx = [hinge_in, Sx - hinge_in], k = upper ? [0] : [-1, 1])
    translate([gx + k * (seg_w + seg_gap) - seg_w / 2, 0, 0])
      rotate([90, 0, 90]) linear_extrude(seg_w) knuckle2d(upper);
}

// ---- Base shell ----

module base_shell() {
  difference() {
    union() {
      hull() {
        linear_extrude(0.01) inset2d(bot_ch);
        translate([0, 0, bot_ch]) linear_extrude(base_h - bot_ch - seam_ch) outer2d();
        translate([0, 0, base_h - 0.01]) linear_extrude(0.01) inset2d(seam_ch);
      }
      // lip on the inner half of the rim, it locates the lid
      translate([0, 0, base_h - 0.01]) linear_extrude(lip_h + 0.01) ring2d(wall - lip_t, wall);
    }
    translate([0, 0, floor_t]) linear_extrude(base_h + lip_h) inset2d(wall);
  }
}

module port_cut() {
  translate([0, Sy + 1, 0]) rotate([90, 0, 0]) linear_extrude(wall + 2) translate([px, pz]) win2d();
}

// Dovetail channel in the outer face of the front wall, from under the window up
// through the rim: narrow at the face, wide behind. The slider sits flush in it and
// goes in from the top; the closed lid keeps it in.
module slider_channel() {
  a = sl_w / 2 + 0.2;
  b = sl_w / 2 + sl_t + 0.2;
  translate([px, 0, sl_z0]) linear_extrude(zc + lip_h + 1 - sl_z0)
    polygon([[-a, Sy + 0.01], [a, Sy + 0.01], [b, Sy - sl_t], [b, Sy - sl_t - 0.3], [-b, Sy - sl_t - 0.3], [-b, Sy - sl_t]]);
}

// Two bumps on the channel floor: the hole in the slider tongue clicks over the
// lower one when closed and over the upper one when open.
module slider_bumps() {
  intersection() {
    for (zb = [sl_z0 + 4, sl_z0 + 4 + sl_travel]) translate([px - sl_w / 2 + tg_x, Sy - sl_t - 0.6, zb]) sphere(r = 0.9, $fn = 24);
    translate([px, Sy - sl_t - 0.31, sl_z0]) cube([sl_w, 2, sl_h + sl_travel + 4]);
  }
}

// Boss inside the front wall behind the latch pocket, with a 45 degree underside.
module latch_boss() {
  hull() {
    translate([Sx / 2 - 14, yf - 3, zc - latch_drop - 3]) cube([28, 3.01, latch_drop + 3]);
    translate([Sx / 2 - 14, yf - 0.01, zc - latch_drop - 6]) cube([28, 0.02, 0.01]);
  }
}

// Recess for the flush tongue, a 45 degree lead-in over the wall top, the pocket the
// hook catches in, a scoop for a fingernail under the tongue, and a notch in the
// rim lip where the tongue passes.
module latch_cut() {
  zt = zc - latch_drop;
  translate([Sx / 2 - latch_w / 2 - 0.5, 0, 0]) rotate([90, 0, 90]) linear_extrude(latch_w + 1) {
    translate([Sy - 1.9, zt - 0.5]) square([3, latch_drop + 2]);
    polygon([[Sy - 1.89, zc - 1], [Sy - 1.89, zc + 1], [Sy - 2.9, zc + 1], [Sy - 2.9, zc]]);
    polygon([[Sy - 1.89, zt - 0.2], [Sy - 2.9, zt + 0.81], [Sy - 2.9, zt + 1.59], [Sy - 1.89, zt + 2.6]]);
    polygon([[Sy - 1.9, zt - 0.49], [Sy + 1, zt - 0.49], [Sy + 1, zt - 3.4]]);
  }
  translate([Sx / 2 - latch_w / 2 - 0.6, Sy - wall - 0.2, zc - 0.01]) cube([latch_w + 1.2, wall + 1.2, lip_h + 1]);
}

module base() {
  difference() {
    union() {
      base_shell();
      knuckles(false);
      latch_boss();
    }
    port_cut();
    slider_channel();
    latch_cut();
  }
  slider_bumps();
}

// ---- Whoop tray ----
// Fills the whoop side of the shell up to deck_h, with a pocket around the ducts of
// one whoop. No floor under the pocket: the whoop stands on the floor of the shell.

module whoop_tray() {
  translate([0, 0, fz]) linear_extrude(deck_h) difference() {
    intersection() {
      inset2d(wall + t_clr);
      translate([x_cz + t_clr, 0]) square([Sx, Sy]);
    }
    translate([dx, dy]) offset(r = c_clr) whoop2d(sq, duct_d);
  }
}

// ---- Charger tray and click jaws ----
// The tray fills the charger side up to ct_h, with a pocket in the front right corner
// open to the front and the outer wall, so the charger meets both. Behind the pocket
// run two dovetail grooves, one for each jaw, with a row of sawtooth teeth on their
// floor that rise toward the charger. Local frame of a groove or a jaw: u toward the
// charger, w across, z from the top of the tray; the pocket face at u = 0.

module jaw_groove(lc) {
  translate([-lc, 0, 0]) rotate([90, 0, 90]) linear_extrude(lc + 1)
    polygon([[-4.0, 0.01], [4.0, 0.01], [5.5, -1.5], [5.5, -5.3], [-5.5, -5.3], [-5.5, -1.5]]);
}

module jaw_teeth(lc) {
  translate([0, 5.5, 0]) rotate([90, 0, 0]) linear_extrude(11)
    for (i = [0 : floor(lc) - 1]) polygon([[-lc + i, -5.31], [-lc + i + 1, -4.5], [-lc + i + 1, -5.31]]);
}

module at_side_groove() {
  translate([x_pw, y_ji, fz + ct_h]) rotate(180) children();
}

module at_rear_groove() {
  translate([x_jr, y_pr, fz + ct_h]) rotate(90) children();
}

module charger_tray() {
  difference() {
    translate([0, 0, fz]) linear_extrude(ct_h) difference() {
      intersection() {
        inset2d(wall + t_clr);
        square([x_cz - t_clr, Sy]);
      }
      translate([-1, y_pr]) square([x_pw + 1, Sy]);
    }
    at_side_groove() jaw_groove(l_side + 0.5);
    at_rear_groove() jaw_groove(l_rear + 0.5);
  }
  at_side_groove() jaw_teeth(l_side + 0.5);
  at_rear_groove() jaw_teeth(l_rear + 0.5);
}

// A click jaw, length len. The body rides on the tray, the slider below it runs in
// the dovetail. The lower slab of the slider is a pawl arm, freed by a thin gap and
// rooted at the front, with a tooth under its rear end that drops into the teeth of
// the groove: the jaw slides toward the charger and clicks, but not back. A post on
// the rear end of the arm rises through a slot to above the jaw: lift it to slide
// the jaw back. The lip on the face has a 45 degree underside and hooks over the
// charger.
module jaw(len) {
  zl = charger_h - ct_h + 0.3;
  zb = -4.2;
  difference() {
    union() {
      translate([-len, -5.3, 0]) cube([len, 10.6, jaw_h]);
      translate([-len, 0, 0]) rotate([90, 0, 90]) linear_extrude(len)
        polygon([[-3.8, 0.01], [3.8, 0.01], [5.3, -1.5], [5.3, zb], [-5.3, zb], [-5.3, -1.5]]);
      translate([0, 5.3, 0]) rotate([90, 0, 0]) linear_extrude(10.6) {
        polygon([[-0.01, zl], [1.2, zl + 1.2], [1.2, zl + 1.6], [-0.01, zl + 2.8]]);
        polygon([[-len + 0.3, zb + 0.01], [-len + 0.3, zb - 0.8], [-len + 1.3, zb + 0.01]]);
      }
    }
    // the gap over the pawl arm, open at the rear
    translate([-len - 1, -6, zb + 1.2]) cube([len - 1.5, 12, 0.7]);
    // the slot the release post rises through, open at the rear
    translate([-len - 1, -1.9, zb + 1.2]) cube([3.3, 3.8, jaw_h + 6]);
  }
  // the release post, standing on the rear end of the pawl arm
  translate([-len + 0.3, -1.5, zb + 1.19]) cube([1.6, 3, jaw_h + 2 - zb - 1.19]);
}

// The jaws as fitted against the ghost charger: the side jaw pushes toward the outer
// wall, the rear jaw toward the front wall.
module jaws_placed() {
  translate([wall + gh_w, y_ji, fz + ct_h]) rotate(180) jaw(l_side);
  translate([x_jr, yf - gh_l, fz + ct_h]) rotate(90) jaw(l_rear);
}

// Printed on its side, so the pawl arm bends along its layers.
module jaw_flat(len) {
  translate([len, 0, 5.3]) rotate([90, 0, 0]) jaw(len);
}

module jaws_flat() {
  jaw_flat(l_side);
  translate([0, -(jaw_h + 14), 0]) jaw_flat(l_rear);
}

// ---- Port slider ----
// Prints back face down; its edges narrow at 45 degrees toward the front, into the
// dovetail. A tongue cut into it beside the window bends along its layers; the hole
// at its tip clicks over the bumps in the channel. Two grooves across the top of the
// front give the thumb a grip. Local frame: x across, y up the wall, z from the back
// face to the front.

module slider_flat() {
  difference() {
    hull() {
      translate([-sl_t, 0, 0]) cube([sl_w + 2 * sl_t, sl_h, 0.01]);
      translate([0, 0, sl_t - 0.01]) cube([sl_w, sl_h, 0.01]);
    }
    difference() {
      translate([tg_x - 2.1, 1.4, -1]) cube([4.2, 10.6, sl_t + 2]);
      translate([tg_x - 1.5, 2, -2]) cube([3, 11, sl_t + 4]);
    }
    translate([tg_x, 4, -1]) cylinder(d = 1.8, h = sl_t + 2, $fn = 24);
    for (gy = [14.2, 15.4]) translate([-sl_t - 1, gy - 0.4, sl_t - 0.6]) cube([sl_w + 2 * sl_t + 2, 0.8, 1]);
  }
}

module slider_placed() {
  multmatrix([[1, 0, 0, px - sl_w / 2], [0, 0, 1, Sy - sl_t], [0, 1, 0, sl_z0], [0, 0, 0, 1]]) slider_flat();
}

// ---- Lid ----

module lid_shell() {
  difference() {
    translate([0, 0, zc]) hull() {
      linear_extrude(0.01) inset2d(seam_ch);
      translate([0, 0, seam_ch]) linear_extrude(lid_h - seam_ch - top_ch) outer2d();
      translate([0, 0, lid_h - 0.01]) linear_extrude(0.01) inset2d(top_ch);
    }
    translate([0, 0, zc - 1]) linear_extrude(lid_cav + 1) inset2d(wall);
    // recess for the lip of the base
    translate([0, 0, zc - 1]) linear_extrude(lip_h + 0.3 + 1) ring2d(wall - lip_t - lip_c, wall + 0.01);
  }
}

// The tongue is the outer skin of the lid front, carried on down past the rim into
// the recess of the base. Its hook rides over the lead-in and catches in the pocket.
module latch_tongue() {
  zt = zc - latch_drop;
  translate([Sx / 2 - latch_w / 2, 0, 0]) rotate([90, 0, 90]) linear_extrude(latch_w) {
    translate([Sy - tongue_t, zt]) square([tongue_t, latch_drop + 4]);
    polygon([[Sy - tongue_t + 0.01, zt], [Sy - 2.7, zt + 1.1], [Sy - 2.7, zt + 1.3], [Sy - tongue_t + 0.01, zt + 2.4]]);
  }
}

// Two slits and a relief behind the tongue free its upper 4 mm from the lid wall,
// so it flexes over latch_drop plus 4 mm.
module tongue_relief() {
  for (s = [-1, 1]) translate([Sx / 2 + s * (latch_w / 2 + 0.3) - 0.3, Sy - wall - 1, zc - 1]) cube([0.6, wall + 2, 5]);
  translate([Sx / 2 - latch_w / 2 - 0.01, Sy - wall - 1, zc - 1]) cube([latch_w + 0.02, wall + 1 - tongue_t, 5]);
}

function bat_x(i) = Sx / 2 + (i - (battery_count - 1) / 2) * bat_pitch;

// 1S batteries stand on their side, thickness across x, plug end along y. Two pairs
// of arms per battery, clip_y either side of the middle, so short and long batteries
// of the family both sit across them; each arm has a 45 degree bump that snaps over
// the free edge. arm_gap between neighbouring arms leaves room for an arm to give
// while the next slot is full.
module bat_clips() {
  if (battery_count > 0)
    for (i = [0 : battery_count - 1], yc = [Sy / 2 - clip_y, Sy / 2 + clip_y], s = [-1, 1]) {
      f = bat_x(i) + s * (battery_t / 2 + bat_clr);
      zb = pb - battery_w - 0.15;
      translate([0, yc + arm_w / 2, 0]) rotate([90, 0, 0]) linear_extrude(arm_w) {
        translate([s < 0 ? f - arm_t : f, pb - battery_w - 1.6]) square([arm_t, battery_w + 1.6 + 0.01]);
        polygon([[f + s * 0.01, zb], [f - s * bump, zb - bump], [f + s * 0.01, zb - 2 * bump]]);
      }
    }
}

module lid() {
  difference() {
    union() {
      lid_shell();
      knuckles(true);
      bat_clips();
      latch_tongue();
    }
    tongue_relief();
  }
}

module lid_print() {
  translate([0, Sy, zc + lid_h]) rotate([180, 0, 0]) lid();
}

// ---- Ghost contents ----

module ghost_whoop() {
  color("Gainsboro", 0.5) translate([dx, dy, fz]) {
    for (sx = [-1, 1], sy = [-1, 1]) translate([sx * sq / 2, sy * sq / 2, 0])
      difference() { cylinder(d = duct_d, h = 16); translate([0, 0, -1]) cylinder(d = duct_d - 2, h = 18); }
    translate([-12, -16, 0]) cube([24, 32, whoop_h]);
  }
}

module ghost_charger() {
  color("OrangeRed", 0.5) translate([wall, yf - gh_l, fz]) cube([gh_w, gh_l, charger_h]);
}

module ghost_batteries() {
  if (battery_count > 0)
    color("DimGray", 0.6) for (i = [0 : battery_count - 1])
      translate([bat_x(i) - battery_t / 2, Sy / 2 - battery_l / 2, pb - battery_w]) cube([battery_t, battery_l, battery_w]);
}

// ---- Test coupons ----

module coupon(lo, hi) {
  translate(-lo) intersection() { children(); translate(lo) cube(hi - lo); }
}

module test_layout() {
  g = 46;
  // hinge, base and lid half
  coupon([hinge_in - 16, -hk - rk - 1, zc - 14], [hinge_in + 16, 6, zc + lip_h + 1]) base();
  translate([0, 22, 0]) coupon([hinge_in - 16, Sy - 6, 0], [hinge_in + 16, Sy + hk + rk + 1, lid_h + 12]) lid_print();
  // latch, base and lid half
  translate([g, 0, 0]) coupon([Sx / 2 - 16, Sy - 7, zc - latch_drop - 8], [Sx / 2 + 16, Sy + 0.1, zc + lip_h + 1]) base();
  translate([g, 22, 0]) coupon([Sx / 2 - 16, -0.1, 0], [Sx / 2 + 16, 7, lid_h + latch_drop + 1]) lid_print();
  // slider channel with the window, and the slider
  translate([2 * g, 0, 0]) coupon([px - 17, Sy - 5, max(0, sl_z0 - 3)], [px + 17, Sy + 0.1, zc + 0.5]) base();
  translate([2 * g + 4, 12, 0]) slider_flat();
  // a strip of charger tray with the side groove and its teeth, and the side jaw
  translate([3 * g, 0, 0]) coupon([x_pw - 2, y_ji - 9, fz], [x_cz - t_clr + 0.1, y_ji + 9, fz + ct_h]) charger_tray();
  translate([3 * g, jaw_h + 26, 0]) jaw_flat(l_side);
  // one battery clip
  if (battery_count > 0) {
    yc = Sy / 2 - clip_y;
    bx = bat_x(0);
    translate([4 * g, 0, 0])
      coupon([bx - bat_pitch / 2 - 1, Sy - yc - arm_w / 2 - 4, 0], [bx + bat_pitch / 2 + 1, Sy - yc + arm_w / 2 + 4, lid_h + 1]) lid_print();
  }
}

// ---- Layout ----

module assembly() {
  color(color_case) base();
  color(color_case) whoop_tray();
  color(color_case) charger_tray();
  color(color_case) jaws_placed();
  color(color_case) slider_placed();
  if (show_contents) { ghost_whoop(); ghost_charger(); }
  // lid swung open flat behind the base
  translate([0, -hk, zc]) rotate([180, 0, 0]) translate([0, hk, -zc]) {
    color(color_case) lid();
    if (show_contents) ghost_batteries();
  }
}

if (test_print) color(color_case) test_layout();
else if (part == "base") color(color_case) base();
else if (part == "lid") color(color_case) lid_print();
else if (part == "whoop_tray") color(color_case) translate([0, 0, -fz]) whoop_tray();
else if (part == "charger_tray") color(color_case) translate([0, 0, -fz]) charger_tray();
else if (part == "jaws") color(color_case) jaws_flat();
else if (part == "slider") color(color_case) slider_flat();
else assembly();