// CyberDeck case — CLAMSHELL
// Two-part hinged laptop-style shell: keyboard deck on the bottom half,
// touchscreen + Pi + LoRa board on the lid, joined by a printed pivot hinge.
// Fits: Raspberry Pi 4/5, Meshtastic-class LoRa board, 5-7" DSI/HDMI display,
// BB Q10/Q20-class keyboard. See ../bom.json for source hardware.
//
// Print settings: 0.2mm layer height, 25% infill, supports ON for the hinge
// knuckles only (use "supports touching build plate" if your slicer allows
// per-feature support painting). PETG recommended for the hinge (better
// layer adhesion under repeated flex than PLA).
//
// Compile: openscad -o clamshell.stl clamshell.scad

// ---- hardware envelope (from bom.json) ----
pi_w = 85;  pi_d = 56;  pi_h = 17;
lora_w = 51; lora_d = 26; lora_h = 14;
disp_w = 194; disp_d = 110; disp_h = 20;
kb_w = 116; kb_d = 43; kb_h = 10;

wall = 3;
gap  = 4;      // clearance around each component
hinge_len = 90;
hinge_r   = 6;

lid_w = disp_w + 2*(wall+gap);
lid_d = disp_d + 2*(wall+gap);
lid_h = disp_h + wall + 6;   // + room for Pi/LoRa stacked behind the panel

base_w = lid_w;
base_d = max(kb_d + 2*(wall+gap), 70);
base_h = kb_h + wall + 8;

function max(a,b) = a > b ? a : b;

module rounded_box(w,d,h,r=3) {
  hull() {
    for (x=[r, w-r]) for (y=[r, d-r])
      translate([x,y,0]) cylinder(r=r, h=h, $fn=32);
  }
}

module logo_badge(w) {
  // engraved wordmark badge, cut into the underside of the base
  translate([w/2, 10, 0])
    linear_extrude(height=0.6)
      text("PERFECT WORLD PROJECT", size=4.2, halign="center", valign="center",
           font="Liberation Sans:style=Bold");
}

module base_shell() {
  difference() {
    rounded_box(base_w, base_d, base_h, 4);
    // keyboard cavity
    translate([wall+gap, wall+gap, wall])
      cube([kb_w, kb_d, kb_h+2]);
    // hollow interior below wall thickness
    translate([wall, wall, wall])
      cube([base_w-2*wall, base_d-2*wall, base_h]);
  }
  // engraved logo on the front lip, raised text (embossed, not cut)
  translate([base_w/2, base_d-6, base_h])
    linear_extrude(height=0.6)
      text("PWP", size=6, halign="center", valign="center",
           font="Liberation Sans:style=Bold");
  // hinge knuckles (male) along the back edge
  for (x=[10, base_w-10-hinge_r*2])
    translate([x, base_d-hinge_r, base_h])
      rotate([0,90,0])
        cylinder(r=hinge_r, h=hinge_r*2, $fn=48);
}

module lid_shell() {
  difference() {
    rounded_box(lid_w, lid_d, lid_h, 4);
    translate([wall+gap, wall+gap, wall+2])
      cube([disp_w, disp_d, disp_h+2]);
    translate([wall, wall, wall])
      cube([lid_w-2*wall, lid_d-2*wall, lid_h]);
  }
  logo_badge(lid_w);
  // hinge sockets (female), offset to interlock with base knuckles
  translate([0,0,0])
  for (x=[10+hinge_r*2+1, lid_w-10-hinge_r*4-1])
    translate([x, lid_d-1, 0])
      rotate([0,90,0])
        difference(){
          cylinder(r=hinge_r+1.2, h=hinge_r*2+2, $fn=48);
          translate([0,0,-1]) cylinder(r=hinge_r+0.4, h=hinge_r*2+4, $fn=48);
        }
}

// Layout: base on plate, lid printed alongside, flat, hinge-open
translate([0,0,0]) base_shell();
translate([base_w+20, 0, 0]) lid_shell();