More accurate keycap socket

BUTTON/popn_keycap.scad

@@ -1,49 +1,76 @@
-gap_w = 1.19; // 1.17 +/-0.02
+gap_w = 1.16; // socket cross width
-gap_h = 4.15; // 4.1 +0.05
+gap_h = 3.98;  // socket cross height
-stem_l = 4.8;
+gap_r = 0.15; // radius of round corner in cross
+stem_l = 4.3; // socket stem length
+stem_d = 5.6; // socket stem diameter
 
 
 difference() {
-    translate([0,0,3]) difference() {
+  union() {
-        bean([28,28,10]); 
+    cap();
-        translate([0,0,-1.5]) bean([25,25,10]);
+    stem();
-    }
+  }
-    translate([-50,-50,-100]) cube([100,100,100]);    
+  socket();
+  //bevel();
 }
 
-stem();
-
 //color("green", 0.3) translate([0,0,0]) cylinder(d=28,h=8);
 //color("red", 0.6) translate([0,0,0]) cylinder(d=8,h=3);
 //color("blue", 0.6) translate([0,0,3]) cylinder(d=9,h=stem_l);
 
-module bean(x) {
+module cap() {
-    resize(x) minkowski() {
+  difference() {
-        difference() {
+    translate([0,0,3]) difference() {
-            translate([0,0,-1.8]) resize([30,30,5]) sphere(d=50,$fn=96);
+      translate([0,0,0]) bean([28,28,10]); 
-            translate([-50,-50,-100]) cube([100,100,100]);
+      translate([0,0,-1.5]) bean([25,25,10]);
-        }
-        sphere(d=7,$fn=64);
     }
+    translate([-50,-50,-100]) cube([100,100,100]);  
+  }
+}
+
+module bean(x) {
+  resize(x) minkowski() {
+    difference() {
+      translate([0,0,-1.8]) resize([30,30,5]) sphere(d=50,$fn=96);
+      translate([-50,-50,-100]) cube([100,100,100]);
+    }
+    sphere(d=7,$fn=64);
+  }
 }
 
 module stem() {
-    color("cyan") translate([0,0,8-stem_l-1]) union() {
+  translate([0,0,6.5-stem_l]) {
-        difference() {
+    cylinder(d=stem_d,h=stem_l+1,$fn=64);
-            union() {
+    translate([0,0,stem_l-0.3]) cylinder(d1=5.5,d2=8.5,h=1,$fn=64);
-                cylinder(d=5.5,h=stem_l+1,$fn=64);
+  }
-                hull() {
+}
-                    translate([0,0,stem_l-0.5]) cylinder(d=5.5,h=0.1,$fn=64);
+
-                    translate([0,0,stem_l+1]) cylinder(d=10,h=0.1,$fn=64);
+module socket()
-                }
+{
-            }
+  translate([0,0,6.5-stem_l-0.01]) difference() {
-            translate([0,0,-1]) cube([gap_h,gap_w,20], center=true);
+    l=stem_l+1;
-            translate([0,0,-1]) cube([gap_w,gap_h,20], center=true);
+    union() {
-            translate([0,0,-1]) cube([gap_w+0.3*2,gap_w+0.3*2,20], center=true);
+      translate([0,0,l/2]) cube([gap_h,gap_w,l], center=true);
-        }
+      translate([0,0,l/2]) cube([gap_w,gap_h,l], center=true);
-        translate([-gap_w/2-0.3,-gap_w/2-0.3, 0]) cylinder(d=0.6,h=4.5,$fn=24);
+      translate([0,0,l/2]) cube([gap_w+gap_r*2,gap_w+gap_r*2,l], center=true);
-        translate([gap_w/2+0.3,-gap_w/2-0.3, 0]) cylinder(d=0.6,h=4.5,$fn=24);
+    }
-        translate([-gap_w/2-0.3,gap_w/2+0.3, 0]) cylinder(d=0.6,h=4.5,$fn=24);
+    
-        translate([gap_w/2+0.3,gap_w/2+0.3, 0]) cylinder(d=0.6,h=4.5,$fn=24);
+    r = gap_w/2 + gap_r;
-    }
+    for (i=[-1,1]) {
+      for (j=[-1,1]) {
+        translate([i*r,j*r,-1]) cylinder(r=gap_r,h=l+2,$fn=24);
+      }
+    }
+  }
+}
+
+module bevel() {
+  color("red", 0.5) translate([0,0,6.5-stem_l]) hull() {
+    translate([0,0,-0.01]) cube([gap_w+0.4, gap_h+0.4, 0.01],center=true);
+    translate([0,0,0.3]) cube([gap_w, gap_h, 0.01],center=true);
+  }
+  color("red", 0.5) hull() {
+    translate([0,0,-0.01]) cube([gap_h+0.4, gap_w+0.4, 0.01],center=true);
+    translate([0,0,0.3]) cube([gap_h, gap_w, 0.01],center=true);
+  }    
 }

README.md

@@ -86,7 +86,7 @@ Thanks to:
    * Make half-transparent resin by mixing translucent and white resin (5:1) as the base resin.
    * Mix some drops of UV resin pigment, you can make all Pop'n Music button colors.  
      <img src="doc/color_pigment.jpg" width="50%">
-   * 3D file is **/PRODUCTION/popn_keycap.stl** or if you're using Chitubox - **/PRODUCTION/popn_6keys.chitubox**. Orientation and support should be like this to get perfect button surface.  
+   * 3D file is **/PRODUCTION/popn_keycap.stl** or if you're using Chitubox - **/PRODUCTION/popn_keycaps.chitubox**. Orientation and support should be like this to get perfect button surface.  
     <img src="doc/button_resin_support.png" width="50%">
 * There're many other choices.
   * Homemade bottle cover keycaps