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Module air_holes condensed #32

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122 changes: 21 additions & 101 deletions 10InchRackGenerator.scad
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Original file line number Diff line number Diff line change
@@ -1,3 +1,6 @@
include <BOSL2/std.scad>
include <BOSL2/walls.scad>

rack_width = 254.0; // [ 254.0:10 inch, 152.4:6 inch]
// Height of the rack in U units, can be a fraction for partial U (e.g. 1.5 for 1U plus half of the next U)
rack_height = 1.0; // [0.5:0.5:5]
Expand Down Expand Up @@ -244,110 +247,29 @@ module switch_mount(switch_width, switch_height, switch_depth) {

// Simplified air holes with staggered honeycomb pattern on all faces
module air_holes() {
hole_d = 16;
spacing_x = 15; // Horizontal spacing (X and Y directions)
spacing_z = 17; // Vertical spacing (Z direction) - tighter to match visual density
margin = 3; // Keep holes away from edges

// Chassis dimensions used by both hole sections
chassis_height = min(switch_height + (2 * case_thickness), height);
chassis_width = min(switch_width + (2 * case_thickness), (rack_width == 152.4) ? 120.65 : 221.5);
side_margin = (rack_width - chassis_width) / 2;

// TOP/BOTTOM FACE HOLES (Y-axis, penetrating top and bottom chassis walls)
// Calculate available space for holes within switch dimensions
available_width = switch_width - (2 * margin);
available_depth = switch_depth - (2 * margin);

// Calculate number of holes that fit
x_cols = floor(available_width / spacing_x);
z_rows = floor(available_depth / spacing_z);

// Calculate actual grid size for centering
actual_grid_width = (x_cols - 1) * spacing_x;
actual_grid_depth = (z_rows - 1) * spacing_z;

// Center the grid within the switch cutout area
cutout_center_x = rack_width / 2;
cutout_center_z = front_plate_thickness + switch_depth / 2;

x_start = cutout_center_x - actual_grid_width / 2;
z_start = cutout_center_z - actual_grid_depth / 2;

// Cylinder must span the full chassis height in Y, including when chassis_height > height
// (chassis body is centered in height, so it can protrude above/below the front panel bounds)
y_hole_top = (height + chassis_height) / 2 + 1;
y_hole_h = chassis_height + 2;

// Create top/bottom face holes with VERTICAL staggered pattern
if (x_cols > 0 && z_rows > 0) {
for (i = [0:x_cols-1]) {
for (j = [0:z_rows-1]) {
// Stagger every other COLUMN (i) instead of row (j) for vertical honeycomb pattern
z_offset = (i % 2 == 1) ? spacing_z/2 : 0;
x_pos = x_start + i * spacing_x;
z_pos = z_start + j * spacing_z + z_offset;

// Only place hole if it fits within bounds after staggering
if (z_pos + hole_d/2 <= cutout_center_z + switch_depth/2 - margin &&
z_pos - hole_d/2 >= cutout_center_z - switch_depth/2 + margin) {
translate([x_pos, y_hole_top, z_pos]) {
rotate([90, 0, 0]) {
cylinder(h = y_hole_h, d = hole_d, $fn = 6);
}
}
hex_strut = 4;
hex_spacing = 15;
hex_bottom_frame = 10;

test_hex_fit_Y = (component_height + case_thickness*2) - ( hex_spacing + hex_bottom_frame*2);
test_hex_fit_x = (component_width + case_thickness*2) - ( hex_spacing + hex_bottom_frame*2);

if(air_holes){
translate([rack_width/2, height/2, component_depth/2]){
if(test_hex_fit_x >= 0){
difference(){
cuboid([component_width + case_thickness*2+.1, component_height + case_thickness*2+.1, component_depth],rounding=0,edges=["Z"]);
hex_panel([component_width + case_thickness*2-.1, component_depth, component_height + case_thickness*2-.1], hex_strut, hex_spacing, frame=hex_bottom_frame, orient=FRONT);
}
}
}
}

// SIDE FACE HOLES (X-axis through left and right walls)

// Calculate available space within chassis height (includes case walls above/below switch)
available_height = chassis_height - (2 * margin);
available_side_depth = switch_depth - (2 * margin);

// Calculate number of holes that fit on sides
y_cols = floor(available_height / spacing_x); // Use spacing_x for Y direction
z_rows_side = floor(available_side_depth / spacing_z);

// Calculate actual grid size for sides
actual_grid_height = (y_cols - 1) * spacing_x;
actual_grid_depth_side = (z_rows_side - 1) * spacing_z;

// Center the grid within the chassis height (Y) and switch depth (Z)
cutout_center_y = height / 2; // Chassis is centered in the 1U height

y_start = cutout_center_y - actual_grid_height / 2;
z_start_side = cutout_center_z - actual_grid_depth_side / 2;

// Each cylinder runs from 1mm outside the left wall all the way through to 1mm outside
// the right wall. Using a single cylinder per position avoids the right-side cylinder
// going in the wrong direction (away from the chassis).
if (y_cols > 0 && z_rows_side > 0) {
for (i = [0:y_cols-1]) {
for (j = [0:z_rows_side-1]) {
// Stagger every other COLUMN (i) instead of row (j) for vertical honeycomb pattern
z_offset = (i % 2 == 1) ? spacing_z/2 : 0;
y_pos = y_start + i * spacing_x;
z_pos = z_start_side + j * spacing_z + z_offset;

// Only place hole if it fits within bounds after staggering
if (y_pos + hole_d/2 <= cutout_center_y + chassis_height/2 - margin &&
y_pos - hole_d/2 >= cutout_center_y - chassis_height/2 + margin &&
z_pos + hole_d/2 <= cutout_center_z + switch_depth/2 - margin &&
z_pos - hole_d/2 >= cutout_center_z - switch_depth/2 + margin) {
translate([side_margin - 1, y_pos, z_pos]) {
rotate([0, 90, 0]) {
rotate([0, 0, 90]) { // Rotate hexagon 90 degrees to match front/back orientation
cylinder(h = chassis_width + 2, d = hole_d, $fn = 6);
}
}
}
if (test_hex_fit_Y >= 0){
difference(){
cuboid([component_width+ case_thickness*2+.1, component_height + case_thickness*2+.1, component_depth],rounding=0,edges=["Z"]);
hex_panel([ component_depth, component_height + case_thickness*2-.1, component_width+ case_thickness*2-.1], hex_strut, hex_spacing, frame=hex_bottom_frame, orient=LEFT);
}
}
}
}
}
}

// Complete keystone with embossed triangle
Expand Down Expand Up @@ -459,9 +381,7 @@ module switch_mount(switch_width, switch_height, switch_depth) {
if (front_wire_holes) {
power_wire_cutouts();
}
if (air_holes) {
air_holes();
}
if (keystones) {
keystone_front_cutout();
translate([rack_width, 0, 0]) mirror([1, 0, 0]) keystone_front_cutout();
Expand Down