"""Integrated COM-09426 plate, revision 2. Dimensions in mm.
Run with Python 3.12 and requirements.txt installed. Physical fit pending.
The test corner and full plate are cut from the SAME finished geometry.
"""
from pathlib import Path
import json, math
import cadquery as cq
import trimesh
ROOT=Path(__file__).resolve().parent
OUT=ROOT/'files';OUT.mkdir(exist_ok=True)
P=json.loads((ROOT/'parameters.json').read_text())
TOP=25.; BOTTOM=22.; BODY=TOP-P['body_recess_mm']; JX=29.; JY=30.5
# Rotation by 180 degrees moves the ears toward the outer/right plate edge.
CENTERS={'A':(8.61,-8.97),'B':(7.44,10.15)}
def box(w,d,h,x=0,y=0,z=0):
 return cq.Workplane('XY').box(w,d,h,centered=(True,True,False)).translate((x,y,z))
def rr(w,d,h,r,x=0,y=0,z=0):return box(w,d,h,x,y,z).edges('|Z').fillet(r)
def slot(length,width,h,x,y,z):return cq.Workplane('XY').slot2D(length,width).extrude(h).translate((x,y,z))
def globalize(s):return s.translate((JX,JY,0))
plate=cq.importers.importStep(str(ROOT/'references/original-plate.step'))
# Restore only the old joystick recess and central wire hole before recutting.
plate=plate.union(rr(22,22,3,2.1,30,30,BOTTOM))
# Two nut bosses below the plate; 0.8 mm minimum under the shorter screw tip.
boss_bottom=BODY-6.8
for name,(x,y) in CENTERS.items():
 support=BODY+P['ear_support_mm'][name]
 plate=plate.union(globalize(rr(6.4,5.4,TOP-boss_bottom,.6,x,y,boss_bottom)))
 # Pocket seats the ear without drawing it down onto an unsupported ledge.
 if support<TOP:
  plate=plate.cut(globalize(rr(6.6,5.6,TOP-support+1,.65,x,y,support)))
# Body seat: shallow recess with a 2 mm insulating floor; no stand above plate.
plate=plate.cut(globalize(rr(19.8,19.8,8,1,z=BODY)))
# A through-opening directly below the four pads, now facing the nearest key row.
wire_cut=rr(9,4,15,.5,0,-7.5,BODY-10)
plate=plate.cut(globalize(wire_cut))
for name,(x,y) in CENTERS.items():
 # Side-access nut pockets emerge below the plate, opening toward +X.
 plate=plate.cut(globalize(box(14-x+3,3.5,1.6,(x-3+14)/2,y,BODY-5.1)))
 plate=plate.cut(globalize(slot(3.2,2.1,14,x,y,BODY-6.2)))
# Clearance around the existing M3 case pillar; preserves the original plate hole.
pillar_clear=cq.Workplane('XY').center(43,43).circle(4.35).extrude(BOTTOM-boss_bottom).translate((0,0,boss_bottom))
plate=plate.cut(pillar_clear)
# Small corner sample includes the actual outer edge, M3 case hole and adjacent
# switch-opening edges. These retained features help judge the final layout.
corner=plate.intersect(box(30.5,30.5,20,31.75,31.75,12))
results={}
def save(name,shape):
 assert shape.val().isValid() and len(shape.solids().vals())==1,name
 cq.exporters.export(shape,str(OUT/f'{name}.step'))
 # Visible face down, the same orientation for both prints. Nut bosses face up.
 printing=shape.rotate((0,0,0),(1,0,0),180)
 b=printing.val().BoundingBox()
 printing=printing.translate((-(b.xmin+b.xmax)/2,-(b.ymin+b.ymax)/2,-b.zmin))
 path=OUT/f'{name}.stl'
 cq.exporters.export(printing,str(path),tolerance=.02,angularTolerance=.08)
 mesh=trimesh.load_mesh(path);mesh.merge_vertices(digits_vertex=6)
 mesh.update_faces(mesh.nondegenerate_faces());mesh.update_faces(mesh.unique_faces())
 mesh.remove_unreferenced_vertices()
 assert mesh.is_watertight and mesh.is_volume,name
 assert len(mesh.split())==1,name
 mesh.export(path)
 results[name]={'size_mm':mesh.extents.tolist(),'volume_mm3':float(mesh.volume),'watertight':True,'connected_solids':1,'print_z_min':float(mesh.bounds[0,2])}
save('PRINT_FIRST_joystick_corner_v2',corner)
save('WAIT_full_top_plate_v2',plate)
# Re-use the reference used for v1 and rotate it to the outer side of the plate.
ref=cq.importers.importStep(str(ROOT/'references/marbastlib-PNT_psp1000.step'))
ref=ref.rotate((0,0,0),(1,0,0),90).rotate((0,0,0),(0,0,1),90).translate((-9.25,-9.25,0))
ref=ref.rotate((0,0,0),(0,0,1),180).translate((JX,JY,BODY))
case=cq.importers.importStep(str(ROOT/'references/original-case.step'))
def overlap(a,b):return a.intersect(b).val().Volume()
results['reference_joystick_overlap_mm3']=overlap(plate,ref)
results['existing_case_overlap_mm3']=overlap(plate,case)
assert results['reference_joystick_overlap_mm3']<.001,results
assert results['existing_case_overlap_mm3']<.001,results
layouts={'SparkFun':{'A':(8.89,-8.985),'B':(7.375,10.06)},'community':{'A':(8.328428,-8.95),'B':(7.5,10.232119)}}
for label,points in layouts.items():
 for name,(x,y) in points.items():
  shaft=globalize(cq.Workplane('XY').center(x,y).circle(.8).extrude(8).translate((0,0,BODY-6)))
  assert overlap(plate,shaft)<.001,(label,name,'shaft obstruction')
assembly=cq.Assembly(name='INTEGRATED_V2_PHYSICAL_FIT_PENDING')
assembly.add(plate,name='PRINT_full_plate',color=cq.Color(.82,.87,.89))
assembly.add(ref,name='REFERENCE_joystick_NOT_PRINTABLE',color=cq.Color(.2,.2,.2))
hardware=[]
for name,(x,y) in layouts['community'].items():
 top=BODY+(2.5 if name=='A' else 2.)
 screw=cq.Workplane('XY').center(x,y).circle(.8).extrude(8).translate((0,0,top-8))
 head=cq.Workplane('XY').center(x,y).circle(1.5).extrude(1.6).translate((0,0,top))
 socket=cq.Workplane('XY').center(x,y).polygon(6,1.5/math.cos(math.pi/6)).extrude(1).translate((0,0,top+.9))
 screw=globalize(screw.union(head.cut(socket)))
 nut=cq.Workplane('XY').center(x,y).polygon(6,3.2/math.cos(math.pi/6)).extrude(1.3).translate((0,0,BODY-4.95))
 nut=globalize(nut.cut(cq.Workplane('XY').center(x,y).circle(.8).extrude(30)))
 for s in (screw,nut):
  assert overlap(plate,s)<.001,(name,'hardware/plate collision')
  assert overlap(ref,s)<.001,(name,'hardware/joystick collision')
  assert overlap(case,s)<.001,(name,'hardware/case collision')
 assert boss_bottom < top-8 < BODY-5.1
 hardware.extend([screw,nut])
 assembly.add(screw,name='BUY_M1_6x8_'+name,color=cq.Color(.5,.52,.55))
 assembly.add(nut,name='BUY_M1_6_nut_'+name,color=cq.Color(.5,.52,.55))
assembly.save(str(OUT/'reference-assembly_NOT_FOR_PRINTING.step'))
# Verify neighboring keycaps against a conservative 18 mm square footprint.
# Static joystick envelope only; actual thumb-cap sweep still needs a fit check.
for x,y in [(9.525,28.575),(28.575,9.525)]:
 cap=box(18,18,12,x,y,TOP)
 v=overlap(cap,ref)
 assert v<.001,'neighbor keycap reference interference'
 for s in hardware:assert overlap(cap,s)<.001,'neighbor keycap hardware interference'
results['source_plate']= 'Unchanged switch, encoder, touch, status LED and M3 case hole geometry outside joystick area.'
results['mounting']='Same M1.6 x 8 DIN912 screws and M1.6 DIN934 nuts as v1; no loose shims.'
results['limits']=['Physical fit and stiffness unverified.','Stock thumb-cap shape and full travel not accurately modeled; test in all directions.','Printed nut-pocket and screw-slot fit unverified.','Support removal must preserve the body seat and wire opening.','Full plate withheld from recommended printing until corner fit passes.']
(ROOT/'validation.json').write_text(json.dumps(results,indent=2)+'\n')
# Views are rendered from the actual exported geometry, not an invented image.
import matplotlib
matplotlib.use('Agg')
import matplotlib.pyplot as plt
import numpy as np
from mpl_toolkits.mplot3d.art3d import Poly3DCollection
fig=plt.figure(figsize=(14,5),facecolor='#f7f8fa')
render_faces={}
def draw(ax,shape,color):
 faces,colors=render_faces.setdefault(ax,([],[]))
 for solid in shape.solids().vals():
  vs,ts=solid.tessellate(.06);vs=[v.toTuple() for v in vs]
  for t in ts:
   face=[vs[i] for i in t];faces.append(face)
   a,b,c=np.array(face);n=np.cross(b-a,c-a);n=n/max(np.linalg.norm(n),1e-12)
   light=.58+.32*abs(n[2])+.10*abs(n[0])
   colors.append(tuple(np.array(matplotlib.colors.to_rgb(color))*light))
for i,title in enumerate(['1  Test corner — body seat and wire opening','2  Joystick secured — no separate shims','3  Underside — two nut pockets']):
 ax=fig.add_subplot(1,3,i+1,projection='3d',facecolor='#f7f8fa');draw(ax,corner,'#82b8c9')
 if i==1:
  draw(ax,ref,'#41454a')
  for s in hardware:draw(ax,s,'#a9acaf')
 faces,colors=render_faces[ax]
 ax.add_collection3d(Poly3DCollection(faces,facecolors=colors,edgecolors=(0,0,0,0),linewidth=0,shade=False))
 ax.set(xlim=(15,48),ylim=(15,48),zlim=(16,34));ax.set_box_aspect((33,33,18))
 ax.view_init(elev=-35 if i==2 else 42,azim=135 if i==2 else -55);ax.set_axis_off();ax.set_title(title,fontsize=10)
fig.suptitle('Integrated joystick mount · v2 · print the corner first',fontsize=17)
fig.text(.5,.04,'Two mounting supports are part of the plate. Community reference geometry; physical fit still needs checking.',ha='center',fontsize=10)
fig.savefig(ROOT/'preview.png',dpi=160,bbox_inches='tight');plt.close(fig)
print(json.dumps(results,indent=2))