lots of stuff

* added new hex key shape
* moved corner and side sculpting functions into special variables
* fixed negative inset stems sticking out the top
* added corner smoothing functionality to 3d surface dishes

Author: rsheldiii

TODO.md

@@ -1,5 +1,11 @@
 TODO:
-  * Make flat stem support default
+  * implement key_shape_at_progress which allows you to query for the exact 2d outline of the keycap at a given height
+    * this makes certain functions easier - building the envelope for instance
+    * requires breaking out shape_slice, and creating a polygon of the skin_shape_slice slices
+  * dishes add / remove height from keycaps, particularly spherical dishes
+    * a bandaid solution would be to allow you to modify where the keytop is along the progression of the keycap
+      * you can't just set a new total_depth because of how width_difference and height_difference work
+    * the true solution would be to rewrite how the dishes work to make them very graduated at the edges
   * implement regular polygon for skin extrusions
   * switch to skin-shaped extrusions by default
   * kailh choc has a non-square key unit; should I get that working for layouts etc? 

customizer.scad

@@ -8,13 +8,38 @@
 include <./includes.scad>
 
 
+// $rounded_key = true;
 // example key
-dcs_row(5) legend("⇪", size=9) key();
+// typewriter_row(5) legend("⇪", size=9) resin() key();
 
-// example row
-/* for (x = [0:1:4]) {
-  translate_u(0,-x) dcs_row(x) key();
-} */
+// // example row
+// for(y = [0:1:3]) {
+//  for (x = [0:1:4]) {
+//     translate_u(x + y % 2 * 0.5,y) hex_row(x) key();
+//   }
+// }
+
+// $double_sculpted = true;
+// row_length = len(preonic_mit_layout[0]);
+// simple_layout(preonic_mit_layout) {
+//   $keycap_rotation = 90;
+//   // $stem_type = "choc";
+//   adjusted_column = [-1, -1/2, 0, 1/2, 0, -1/2, -1/2, 0, 1/2, 0, -1/2, -1];
+//   column_value = double_sculpted_column($column, row_length, "2hands");
+//   translate_u(0, adjusted_column[$column]) hex_row($row, column_value) {
+//     key();
+//   }
+// }
+
+// $hull_shape_type = "skin";
+dsa_row(1) key();
+translate_u(1) dsa_row(1) {
+  union() {
+    // $total_depth = 11;
+    $inverted_dish = true;
+    key();
+  }
+}
 
 // example layout
 /* preonic_default("dcs") key(); */

keys.scad

@@ -6,7 +6,7 @@ module 3d_surface_dish(width, height, depth, inverted) {
   // it doesn't have to be dead reckoning for anything but sculpted sides
   // we know the angle of the sides from the width difference, height difference,
   // skew and tilt of the top. it's a pain to calculate though
-  scale_factor = 1.11;
+  scale_factor = 1.05;
   // the edges on this behave differently than with the previous dish implementations
   scale([width*scale_factor/$3d_surface_size/2,height*scale_factor/$3d_surface_size/2,depth])
     rotate([inverted ? 0:180,0,180])

src/dishes/3d_surface.scad

@@ -1,4 +1,8 @@
 module spherical_dish(width, height, depth, inverted){
+  // these variables take into account corner_radius and corner_sculpting, resulting in a more correct dish
+  // they don't fix the core issue though (dishes adding / subtracting height on the edges of the keycap), so I've disabled them
+  // new_width = $key_shape_type == "sculpted_square" ? width - distance_between_circumscribed_and_inscribed($corner_radius + $corner_sculpting(1)) : width;
+  // new_height = $key_shape_type == "sculpted_square" ? height - distance_between_circumscribed_and_inscribed($corner_radius + $corner_sculpting(1)) : height;
 
   //same thing as the cylindrical dish here, but we need the corners to just touch - so we have to find the hypotenuse of the top
   chord = pow((pow(width,2) + pow(height, 2)),0.5); //getting diagonal of the top

src/dishes/spherical.scad

@@ -4,7 +4,7 @@ include <constants.scad>
 // functions need to be explicitly included, unlike special variables, which
 // just need to have been set before they are used. hence this file
 
-function stem_height() = $total_depth - $dish_depth - $stem_inset;
+function stem_height() = $total_depth - ($dish_depth * ($inverted_dish ? -1 : 1))  - $stem_inset;
 
 // cherry stem dimensions
 function outer_cherry_stem(slop) = [7.2 - slop * 2, 5.5 - slop * 2];
@@ -23,6 +23,10 @@ function cherry_cross(slop, extra_vertical = 0) = [
   [1.15 + slop / 3, 4.23 + extra_vertical + slop / 3 + SMALLEST_POSSIBLE],
 ];
 
+// TODO add side_sculpting
+function key_width_at_progress(progress = 0) = $bottom_key_width + ($unit * ($key_length - 1)) - $width_difference;
+function key_height_at_progress(progress = 0) = $bottom_key_height + ($unit * ($key_length - 1)) - $height_difference + $side_sculpting(progress);
+
 // actual mm key width and height
 function total_key_width(delta = 0) = $bottom_key_width + $unit * ($key_length - 1) - delta;
 function total_key_height(delta = 0) = $bottom_key_height + $unit * ($key_height - 1) - delta;
@@ -47,3 +51,7 @@ function extra_keytop_length_for_flat_sides() = ($width_difference * vertical_in
 function add_rounding(p, radius)=[for(i=[0:len(p)-1])[p[i].x,p[i].y, radius]];
 // computes millimeter length from unit length
 function unit_length(length) = $unit * (length - 1) + 18.16;
+
+// if you have a radius of an inscribed circle, this function gives you the extra length for the radius of the circumscribed circle
+// and vice versa. used to find the edge of a rounded_square
+function distance_between_circumscribed_and_inscribed(radius) = (pow(2, 0.5) - 1) * radius;

src/functions.scad

@@ -17,7 +17,7 @@ use <libraries/scad-utils/lists.scad>
 use <libraries/scad-utils/shapes.scad>
 use <libraries/skin.scad>
 
-// key shape including dish. used as the ouside and inside shape in hollow_key(). allows for itself to be shrunk in depth and width / height
+// key shape including dish. used as the outside and inside shape in hollow_key(). allows for itself to be shrunk in depth and width / height
 module shape(thickness_difference, depth_difference=0){
   dished(depth_difference, $inverted_dish) {
     color($primary_color) shape_hull(thickness_difference, depth_difference, $inverted_dish ? 200 : 0);
@@ -46,12 +46,13 @@ module minkowski_object() {
   }
 }
 
-module envelope(depth_difference=0) {
-  s = 1.5;
+module envelope(depth_difference=0, extra_floor_depth=0) {
+  size = 1.5;
+  
   hull(){
-    cube([total_key_width() * s, total_key_height() * s, 0.01], center = true);
+    translate([0,0,extra_floor_depth]) cube([key_width_at_progress(extra_floor_depth / $total_depth) * size, key_height_at_progress(extra_floor_depth / $total_depth) * size, 0.01], center = true);
     top_placement(SMALLEST_POSSIBLE + depth_difference){
-      cube([top_total_key_width() * s, top_total_key_height() * s, 0.01], center = true);
+      cube([top_total_key_width() * size, top_total_key_height() * size, 0.01], center = true);
     }
   }
 }
@@ -64,12 +65,12 @@ module dished(depth_difference = 0, inverted = false) {
     children();
     difference(){
       union() {
-        // envelope is needed to "fill in" the rest of the keycap
-        envelope(depth_difference);
+        // envelope is needed to "fill in" the rest of the keycap. intersections with small objects are much faster than differences with large objects
+        envelope(depth_difference, $stem_inset);
         if (inverted) top_placement(depth_difference) color($secondary_color) _dish(inverted);
       }
       if (!inverted) top_placement(depth_difference) color($secondary_color) _dish(inverted);
-      /* %top_placement(depth_difference) _dish(); */
+      // %top_placement(depth_difference) _dish();
     }
   }
 }
@@ -79,6 +80,7 @@ module dished(depth_difference = 0, inverted = false) {
 module _dish(inverted=$inverted_dish) {
   translate([$dish_offset_x,0,0]) color($secondary_color) 
   dish(top_total_key_width() + $dish_overdraw_width, top_total_key_height() + $dish_overdraw_height, $dish_depth, inverted);
+  // %dish(top_total_key_width() + $dish_overdraw_width, top_total_key_height() + $dish_overdraw_height, $dish_depth, inverted);
 }
 
 // puts its children at each keystem position provided
@@ -239,7 +241,7 @@ module key(inset=false) {
     };
 
     if ($inner_shape_type != "disable") {
-      translate([0,0,-SMALLEST_POSSIBLE]) {
+      translate([0,0,-SMALLEST_POSSIBLE]) { // avoids moire
         inner_total_shape();
       }
     }
@@ -249,10 +251,12 @@ module key(inset=false) {
     };
   }
 
-  // if $stem_inset is less than zero, we add the
+  // semi-hack to make sure negative inset stems don't poke through the top of the keycap
   if ($stem_inset < 0) {
-    stems_and_stabilizers();
-  }
+    dished(0, $inverted_dish) {
+      stems_and_stabilizers();
+    }
+  } 
 }
 
 // actual full key with space carved out and keystem/stabilizer connectors

src/key.scad

@@ -15,6 +15,7 @@ include <key_profiles/cherry.scad>
 include <key_profiles/dss.scad>
 include <key_profiles/asa.scad>
 include <key_profiles/typewriter.scad>
+include <key_profiles/hex.scad>
 
 // man, wouldn't it be so cool if functions were first order
 module key_profile(key_profile_type, row, column=0) {
@@ -38,6 +39,8 @@ module key_profile(key_profile_type, row, column=0) {
     grid_row(row, column) children();
   } else if (key_profile_type == "typewriter") {
     typewriter_row(row, column) children();
+  } else if (key_profile_type == "hex") { // reddit.com/r/MechanicalKeyboards/comments/kza7ji
+    hex_row(row, column) children();
   } else if (key_profile_type == "hexagon") {
     hexagonal_row(row, column) children();
   } else if (key_profile_type == "octagon") {

src/key_profiles.scad

@@ -13,7 +13,12 @@ module asa_row(row=3, column = 0) {
   $top_skew = 1.75;
   $stem_inset = 1.2;
   $height_slices = 10;
+
   $corner_radius = 1;
+  $more_side_sculpting_factor = 0.4;
+
+  $side_sculpting = function(progress) (1 - progress) * 4.5;
+  $corner_sculpting = function(progress) pow(progress, 2);
 
   // this is _incredibly_ intensive
   //$rounded_key = true;

src/key_profiles/asa.scad

@@ -11,8 +11,15 @@ module dsa_row(row=3, column = 0) {
   $dish_skew_x = 0;
   $dish_skew_y = 0;
   $height_slices = 10;
-  $enable_side_sculpting = true;
+
+  $dish_type = "3d surface";
+  $surface_function = spherical_surface;
+
+  $side_sculpting = function(progress) (1 - progress) * 4.5;
+  $corner_sculpting = function(progress) pow(progress, 2);
+  
   $corner_radius = 1;
+  $more_side_sculpting_factor = 0.4;
 
   $top_tilt_y = side_tilt(column);
   extra_height = $double_sculpted ? extra_side_tilt_height(column) : 0;