include <design.scad>
include <helpers.scad>

// `Heat` in module name means heat brass threaded insert

// in scanner coords:
// Z facing towards laser beam
// X facing right on laser beam plane
// Y facing top (for scanner body)
hole_side_front = [90, 0, 0];
hole_side_back = [-90, 0, 0];
hole_side_top = [180, 0, 0];
hole_side_bottom = [0, 0, 0];
hole_side_left = [0, 90, 0];
hole_side_right = [0, -90, 0];

hole_insert_height = 4;
m2_head_diameter = 3.75;
m2_head_height = 1.9;
m2 = 2;

padding_around_insert = 2;

// gw - glass width
// gh - glass height
// gt - glass thickness
// gcr - glass corner radius
module glass_hole(gw, gh, gt, gcr)
{
    wt = $scannerBodyWallThicknessMm;
    padding_around_glass = 0.4;
    padding_under_glass = 1;
    
    pag = padding_around_glass;
    pug = padding_under_glass;
    
    // visualize glass
    color("yellow", 0.5)
    hull()
    {
        for (x_mult = [-1, 1], y_mult = [-1, 1])
        {
            translate([
                (-gw / 2 + gcr) * x_mult,
                (-gh / 2 + gcr) * y_mult,
                0])
            cylinder($fn = dToFn(gcr * 2), r = gcr, h = gt);
        }
    }
    
    // area to cut around glass
    // TODO: create a module for such rounded rects
    color("blue", 0.5)
    hull()
    {
        w = gw + pag * 2;
        h = gh + pag * 2;
        // I'm not sure it's needed, but epoxy should
        // have some thickness as well, and this padding should
        // protect the glass a bit (the glass will not protrude
        // from the scanner body)
        t = gt + pag + $tiny_padding;
        
        for (x_mult = [-1, 1], y_mult = [-1, 1])
        {
            translate([
                (-w / 2 + gcr) * x_mult,
                (-h / 2 + gcr) * y_mult,
                // cut without artifacts
                -$tiny_padding])
            cylinder($fn = dToFn(gcr * 2), r = gcr, h = t);
        }
    }
    
    // area to cut under glass
    color("blue", 0.5)
    hull()
    {
        w = gw - pug * 2;
        h = gh - pug * 2;
        // cut without artifacts
        // area in front of glass is already taken
        // into account above
        t = wt + $tiny_padding;
        
        for (x_mult = [-1, 1], y_mult = [-1, 1])
        {
            translate([
                (-w / 2 + gcr) * x_mult,
                (-h / 2 + gcr) * y_mult,
                0])
            cylinder($fn = dToFn(gcr * 2), r = gcr, h = t);
        }
    }
}

// see `glass_hole` docs for params details
module front_glass_hole(gw, gh, gt, gcr)
{
    rotate([90, 0, 0])
    glass_hole(gw, gh, gt, gcr);
}

// m - bolt deameter, like M2
// id - insert diameter
// il - insert length
// hd - screw head diameter
// hh - screw head height
// hs - hole side, see values above for details
// wt - wall thickness
// TODO: use `bolt` or `screw` everywhere
module screw_hole(m, id, il, hd, hh, hs, wt = $scannerBodyWallThicknessMm)
{
    screw_diameter_delta = 0.2;
    sdd = screw_diameter_delta;
    
    head_diameter_delta = 1;
    hdd = head_diameter_delta;
    
    head_height_delta = 0.1;
    hhd = head_height_delta;
    subwall_thickness = 2;

    rotate(hs)
    {
        // insert cutter
        cylinder($fn = dToFn(id), d = id, h = il);
        
        // screw cutter
        rotate([180, 0, 0])
        {
            // full screw diameter
            fsd = m + sdd;
            translate([0, 0, -$tiny_padding])
            cylinder($fn = dToFn(fsd), d = fsd, h = wt + $tiny_padding * 2);
            
            // screw head cutter
            // full head diameter
            fhd = hd + hdd;
            fhh = hh + hhd;
            echo("hh:", hh);
            echo("fhh:", fhh);
            translate([0, 0, wt - fhh - $tiny_padding])
            cylinder($fn = dToFn(fhd), d = fhd, h = fhh + $tiny_padding * 2);
        }
    }
}

function padded_hole_d(hd = 4) =
    hd + padding_around_insert * 2;

// h - height
// hd - hole diameter
// TODO: support usual holes, not only hot inserts
module hole_holder(h, hd = 4)
{
    d = padded_hole_d(hd);
    cube_size = [d * 2, d / 2, h];

    rotate([90, 0, 90])
    translate([0, d / 2, -h / 2])
    difference()
    {
        union()
        {
            cylinder($fn = dToFn(d), d = d, h = h);
            
            translate([0, -cube_size[1] / 2, h / 2])
            cube(cube_size, center = true);
        }
        
        union()
        {
            translate([-d, 0, -$tiny_padding])
            cylinder($fn = dToFn(d), d = d, h = h + $tiny_padding * 2);
            translate([d, 0, -$tiny_padding])
            cylinder($fn = dToFn(d), d = d, h = h + $tiny_padding * 2);
        }
    }
}

// h - height
// hd - hole (insert) diameter
// hs - hole side, see values above for details
module hole_holder_hot_inserts(h, hd = 4, hs)
{
    d = hd + padding_around_insert * 2;

    rotate(hs)
    difference()
    {
        hole_holder(h = 40, hd = 4);

        // holes for hot inserts
        union()
        {
            translate([-h / 2 - $tiny_padding, 0, d / 2])
            screw_hole(
                m = m2,
                id = hd,
                il = hole_insert_height,
                hd = m2_head_diameter,
                hh = m2_head_height,
                hs = hole_side_left);
                
            translate([h / 2 + $tiny_padding, 0, d / 2])
            screw_hole(
                m = m2,
                id = hd,
                il = hole_insert_height,
                hd = m2_head_diameter,
                hh = m2_head_height,
                hs = hole_side_right);
        }
    }
}

hole_holder_hot_inserts(h = 40, hd = 4, hs = hole_side_top);

*screw_hole(
    m = m2,
    id = 4,
    il = hole_insert_height * 2,
    hd = m2_head_diameter,
    hh = m2_head_height,
    hs = hole_side_bottom);
    
//front_glass_hole(gw = 26.6, gh = 19.6, gt = 2, gcr = 1);

//screw_hole(2);