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add option for keystone jacks #21

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add option for keystone jacks #21

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117 changes: 90 additions & 27 deletions 10InchRackGenerator.scad
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Original file line number Diff line number Diff line change
Expand Up @@ -14,6 +14,13 @@ air_holes = true; // [true:Show air holes, false:Hide air holes]
print_orientation = true; // [true: Place on printbed, false: Facing forward]
tolerance = 0.42;

keystone_jacks = false; // [true:Show keystone jacks, false:Hide keystone jacks]
keystone_count = 2; // [1:8]
keystone_side = 1; // [0:Left of switch, 1:Right of switch, 2:Above switch, 3:Below switch]
keystone_width = 14.94; // Standard keystone cutout width
keystone_height = 16.51; // Standard keystone cutout height
keystone_spacing = 3.0; // Gap between adjacent jacks

/* [Hidden] */
height = 44.45 * rack_height;

Expand Down Expand Up @@ -47,15 +54,15 @@ module switch_mount(switch_width, switch_height, switch_depth) {
cutout_h = switch_height + (2 * tolerance);
cutout_x = (rack_width - cutout_w) / 2;
cutout_y = (height - cutout_h) / 2;

// Helper modules
module capsule_slot_2d(L, H) {
hull() {
translate([-L/2 + H/2, 0]) circle(r=H/2);
translate([L/2 - H/2, 0]) circle(r=H/2);
}
}

module rounded_rect_2d(w, h, r) {
hull() {
translate([r, r]) circle(r=r);
Expand All @@ -73,7 +80,7 @@ module switch_mount(switch_width, switch_height, switch_depth) {
translate([width - radius, height - radius, 0]) cylinder(h = depth, r = radius);
}
}

// Create the main body as a separate module
module main_body() {
side_margin = (rack_width - chassis_width) / 2;
Expand All @@ -89,7 +96,7 @@ module switch_mount(switch_width, switch_height, switch_depth) {
}
}
}

// Create switch cutout with proper lip
module switch_cutout() {
lip_thickness = 1.2;
Expand All @@ -112,7 +119,7 @@ module switch_mount(switch_width, switch_height, switch_depth) {
cube([cutout_w, cutout_h, chassis_depth_main]);
}
}

// Create all rack holes
module all_rack_holes() {
// Rack standard: 3 holes per U, with specific positioning
Expand All @@ -131,10 +138,10 @@ module switch_mount(switch_width, switch_height, switch_depth) {
// Second hole: 22.225mm from top of U (middle)
// Third hole: 38.1mm from top of U (6.35mm from bottom)
u_hole_positions = [6.35, 22.225, 38.1]; // positions within each U

// Calculate how many full and partial U units we need to consider
max_u = ceil(rack_height); // Include partial U units

for (side_x = [hole_left_x, hole_right_x]) {
for (u = [0:max_u-1]) {
for (hole_pos = u_hole_positions) {
Expand Down Expand Up @@ -173,7 +180,60 @@ module switch_mount(switch_width, switch_height, switch_depth) {
}
}
}


// Keystone jack cutouts on the front panel
module keystone_cutouts() {
kw = keystone_width + 2*tolerance;
kh = keystone_height + 2*tolerance;
pitch_h = kw + keystone_spacing;
pitch_v = kh + keystone_spacing;
total_w = keystone_count * kw + (keystone_count - 1) * keystone_spacing;
total_h = keystone_count * kh + (keystone_count - 1) * keystone_spacing;

// Vertical centering for horizontal (side) layouts
row_y = (height - kh) / 2;

// Gutter widths on the front panel
left_free = (rack_width - cutout_w) / 2;
right_free = (rack_width - cutout_w) / 2;
top_free = (height - cutout_h) / 2;
bottom_free = (height - cutout_h) / 2;

cut_depth = case_thickness + 2*tolerance;

if (keystone_side == 0) {
// Left of switch, row centered in the left gutter
gutter_center = left_free / 2;
start_x = gutter_center - total_w / 2;
for (i = [0:keystone_count-1])
translate([start_x + i*pitch_h, row_y, -tolerance])
cube([kw, kh, cut_depth]);
} else if (keystone_side == 1) {
// Right of switch, row centered in the right gutter
gutter_center = rack_width - right_free / 2;
start_x = gutter_center - total_w / 2;
for (i = [0:keystone_count-1])
translate([start_x + i*pitch_h, row_y, -tolerance])
cube([kw, kh, cut_depth]);
} else if (keystone_side == 2) {
// Above switch, row centered horizontally
top_gutter_center = height - top_free / 2;
start_y = top_gutter_center - kh / 2;
start_x = (rack_width - total_w) / 2;
for (i = [0:keystone_count-1])
translate([start_x + i*pitch_h, start_y, -tolerance])
cube([kw, kh, cut_depth]);
} else {
// Below switch, row centered horizontally
bot_gutter_center = bottom_free / 2;
start_y = bot_gutter_center - kh / 2;
start_x = (rack_width - total_w) / 2;
for (i = [0:keystone_count-1])
translate([start_x + i*pitch_h, start_y, -tolerance])
cube([kw, kh, cut_depth]);
}
}

// Create zip tie holes and indents
module zip_tie_features() {
// Zip tie holes
Expand All @@ -183,7 +243,7 @@ module switch_mount(switch_width, switch_height, switch_depth) {
cube([zip_tie_hole_width, height, zip_tie_hole_length]);
}
}

// Zip tie indents (top and bottom)
x_pos = (rack_width - switch_width)/2;
chassis_height = switch_height + (2 * case_thickness);
Expand All @@ -203,27 +263,27 @@ module switch_mount(switch_width, switch_height, switch_depth) {
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

// BACK FACE HOLES (Y-axis through back)
// 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_thickness + switch_depth / 2;

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

// Create back face holes with VERTICAL staggered pattern
if (x_cols > 0 && z_rows > 0) {
for (i = [0:x_cols-1]) {
Expand All @@ -232,9 +292,9 @@ module switch_mount(switch_width, switch_height, switch_depth) {
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 &&
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, height, z_pos]) {
rotate([90, 0, 0]) {
Expand All @@ -245,44 +305,44 @@ module switch_mount(switch_width, switch_height, switch_depth) {
}
}
}

// SIDE FACE HOLES (X-axis through left and right sides)
// Calculate chassis dimensions
chassis_width = min(switch_width + (2 * case_thickness), (rack_width == 152.4) ? 120.65 : 221.5);
side_margin = (rack_width - chassis_width) / 2;

// Calculate available space within switch height
available_height = switch_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 switch cutout area (Y and Z)
cutout_center_y = height / 2; // Center of the 1U height

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

// Create holes on both left and right sides with VERTICAL staggered pattern
if (y_cols > 0 && z_rows_side > 0) {
for (side = [0, 1]) { // 0 = left side, 1 = right side
side_x = side == 0 ? side_margin : rack_width - side_margin;

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 (z_pos + hole_d/2 <= cutout_center_z + switch_depth/2 - margin &&
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([side_x, y_pos, z_pos]) {
rotate([0, 90, 0]) {
Expand Down Expand Up @@ -312,6 +372,9 @@ module switch_mount(switch_width, switch_height, switch_depth) {
if (air_holes) {
air_holes();
}
if (keystone_jacks) {
keystone_cutouts();
}
}
}
}
Expand Down