// GFCI Paddle Switch Plate
// Parametric recreation of standard Decora/GFCI wall plate
// Rebuilt from STL analysis - fully editable

include <BOSL2/std.scad>

/* [Plate Dimensions] */
// Overall plate dimensions (at top surface)
plate_width = 83.64;        // mm - X dimension
plate_height = 126.64;      // mm - Y dimension
plate_thickness = 5.0;      // mm - Z dimension

/* [Bevel Settings] */
// Bevel creates the tapered edge (top wider than bottom)
bevel_inset = 1.82;         // mm - how much smaller bottom is per side
bevel_height = 3.0;         // mm - height of beveled section (from top)

/* [Recess Settings] */
// Back recess that fits over electrical box
recess_enabled = true;
recess_depth = 2.0;         // mm - depth of recess (from bottom)
recess_inset = 8.0;         // mm - inset from outer edge on each side

/* [Paddle Opening] */
// Rectangular opening for paddle switch
opening_width = 34.0;       // mm - width of opening
opening_height = 67.0;      // mm - height of opening

/* [Corner Rounding] */
plate_corner_radius = 3.0;  // mm - outer corner radius
opening_corner_radius = 2.0; // mm - opening corner radius

/* [Screw Holes] */
screw_holes_enabled = true;
screw_hole_diameter = 4.0;  // mm
screw_hole_spacing = 83.3;  // mm - distance between screw holes (center to center)

/* [Resolution] */
$fn = 64;   // smoothness for curves

// ============================================
// CALCULATED VALUES
// ============================================

// Bottom dimensions (smaller due to bevel)
bottom_width = plate_width - (bevel_inset * 2);
bottom_height = plate_height - (bevel_inset * 2);

// Recess dimensions
recess_width = plate_width - (recess_inset * 2);
recess_height = plate_height - (recess_inset * 2);

// ============================================
// MODULES
// ============================================

// Main plate body with beveled edges
module plate_body() {
    // Flipped for printing: front face (larger) at Z=0, back (smaller) at Z=5
    // This eliminates overhang on beveled edges
    prismoid(
        size1 = [plate_width, plate_height],      // front face (larger) at bottom
        size2 = [bottom_width, bottom_height],    // back face (smaller) at top
        h = plate_thickness,
        rounding = plate_corner_radius,
        anchor = BOTTOM
    );
}

// Back recess for electrical box fit
module back_recess() {
    if (recess_enabled) {
        recess_rounding = max(0.5, plate_corner_radius - recess_inset/4);
        // Recess now at top (Z=5) since plate is flipped for printing
        translate([0, 0, plate_thickness - recess_depth - 0.01])
            prismoid(
                size1 = [recess_width, recess_height],
                size2 = [recess_width, recess_height],
                h = recess_depth + 0.02,
                rounding = recess_rounding,
                anchor = BOTTOM
            );
    }
}

// 2D paddle opening shape (simple rectangle with rounded corners)
module paddle_opening_2d() {
    rect([opening_width, opening_height], rounding=opening_corner_radius);
}

// 3D paddle opening (for subtraction)
module paddle_opening_3d() {
    translate([0, 0, -0.1])
        linear_extrude(height = plate_thickness + 0.2)
            paddle_opening_2d();
}

// Screw holes
module screw_holes() {
    if (screw_holes_enabled) {
        // Top screw hole
        translate([0, screw_hole_spacing/2, -0.1])
            cylinder(h = plate_thickness + 0.2, d = screw_hole_diameter);

        // Bottom screw hole
        translate([0, -screw_hole_spacing/2, -0.1])
            cylinder(h = plate_thickness + 0.2, d = screw_hole_diameter);
    }
}

// ============================================
// MAIN ASSEMBLY
// ============================================

module gfci_paddle_plate() {
    difference() {
        plate_body();
        back_recess();
        paddle_opening_3d();
        screw_holes();
    }
}

// Render the plate
gfci_paddle_plate();

// ============================================
// PREVIEW HELPERS (uncomment to debug)
// ============================================

// Preview just the 2D opening shape:
// paddle_opening_2d();

// Preview the opening position:
// #paddle_opening_3d();

// Preview cross-section (cut in half):
// difference() {
//     gfci_paddle_plate();
//     translate([0, -100, -1]) cube([200, 200, 20]);
// }