openscad-models/light-switches/gfci-paddle-switch-extended-offset.scad

// GFCI Paddle Switch Plate - Extended Size with X Offset
// Custom oversized plate with OFF-CENTER paddle opening
// Opening and screw holes at X=0, plate extends asymmetrically

include <BOSL2/std.scad>

/* [Plate Dimensions] */
// Asymmetric plate: 2.5" left of center, 4.5" right of center
plate_left = 63.5;          // mm (2.5 inches) - distance from center to left edge
plate_right = 114.3;        // mm (4.5 inches) - distance from center to right edge
plate_width = 177.8;        // mm - total X dimension (7 inches)
plate_x_offset = 25.4;      // mm (1 inch) - plate center offset from opening
plate_height = 230.0;       // mm - Y dimension (unchanged)
plate_thickness = 5.0;      // mm - Z dimension

/* [Bevel Settings] */
bevel_inset = 1.82;         // mm - how much smaller bottom is per side

/* [Recess Settings] */
recess_enabled = true;
recess_depth = 2.0;         // mm - depth of recess (from bottom)
recess_inset = 8.0;         // mm - inset from outer edge

/* [Paddle Opening] */
// Rectangular opening for paddle switch (same as standard plate)
opening_width = 34.0;       // mm - width of opening
opening_height = 67.0;      // mm - height of opening

/* [Corner Rounding] */
plate_corner_radius = 3.0;  // mm
opening_corner_radius = 2.0; // mm

/* [Screw Holes] */
screw_holes_enabled = true;
screw_hole_height = 6.0;    // mm - vertical dimension (was diameter)
screw_hole_width = 14.0;    // mm - horizontal dimension (250% of height)
screw_hole_spacing = 83.3;  // mm - distance between main screw holes
main_screw_recess_depth = 3.5;  // mm - depth from back face (Z=5), leaves solid wall on front

// Outer screw holes (smaller, beyond the main holes)
outer_screw_holes_enabled = true;
outer_screw_hole_offset = 6.35;  // mm (0.25 inches) beyond main holes
outer_screw_hole_diameter = 2.68;  // mm (67% of main hole diameter)

// Countersink around outer screw holes (front face)
countersink_enabled = true;
countersink_diameter = 5.0;       // mm - total diameter of recess
countersink_depth = 2.0;          // mm - depth of recess into front face

/* [Resolution] */
$fn = 64;

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

bottom_width = plate_width - (bevel_inset * 2);
bottom_height = plate_height - (bevel_inset * 2);
recess_width = plate_width - (recess_inset * 2);
recess_height = plate_height - (recess_inset * 2);

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

module plate_body() {
    // Flipped for printing: front face (larger) at Z=0, back (smaller) at Z=5
    // This eliminates overhang on beveled edges
    // Offset in X so opening remains at origin
    translate([plate_x_offset, 0, 0])
        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
        );
}

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
        // Offset in X to match plate body
        translate([plate_x_offset, 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);
}

module paddle_opening_3d() {
    translate([0, 0, -0.1])
        linear_extrude(height = plate_thickness + 0.2)
            paddle_opening_2d();
}

module screw_holes() {
    if (screw_holes_enabled) {
        // Main screw holes: recessed from back face (positive Z), solid wall on front
        main_screw_start_z = plate_thickness - main_screw_recess_depth;

        // Top main screw hole (pill-shaped, horizontal)
        translate([0, screw_hole_spacing/2, main_screw_start_z])
            linear_extrude(height = main_screw_recess_depth + 0.1)
                rect([screw_hole_width, screw_hole_height], rounding=screw_hole_height/2);

        // Bottom main screw hole (pill-shaped, horizontal)
        translate([0, -screw_hole_spacing/2, main_screw_start_z])
            linear_extrude(height = main_screw_recess_depth + 0.1)
                rect([screw_hole_width, screw_hole_height], rounding=screw_hole_height/2);
    }

    if (outer_screw_holes_enabled) {
        // Top outer screw hole (above top main hole)
        translate([0, screw_hole_spacing/2 + outer_screw_hole_offset, 0]) {
            // Through-hole
            translate([0, 0, -0.1])
                cylinder(h = plate_thickness + 0.2, d = outer_screw_hole_diameter);
            // Countersink on front face
            if (countersink_enabled)
                translate([0, 0, -0.1])
                    cylinder(h = countersink_depth + 0.1, d = countersink_diameter);
        }

        // Bottom outer screw hole (below bottom main hole)
        translate([0, -screw_hole_spacing/2 - outer_screw_hole_offset, 0]) {
            // Through-hole
            translate([0, 0, -0.1])
                cylinder(h = plate_thickness + 0.2, d = outer_screw_hole_diameter);
            // Countersink on front face
            if (countersink_enabled)
                translate([0, 0, -0.1])
                    cylinder(h = countersink_depth + 0.1, d = countersink_diameter);
        }
    }
}

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

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

gfci_paddle_plate_extended();