from cadgen import build123d as bd

# Millimetres. These are design assumptions until the received boards are measured.
OUT_X = 76.0
OUT_Y = 54.0
BASE_H = 18.0
LID_Z = 17.0
LID_H = 13.0
WALL = 2.4
FIT_CLEARANCE = 0.6
CAM_OPEN_X = 14.0
CAM_OPEN_Z = 6.0
SPEAKER_CENTER_X = 12.0
SPEAKER_CENTER_Y = 0.0
SPEAKER_OPEN_RADIUS = 17.0
MIC_PORT_X = -20.0
MIC_PORT_Z = 10.0
MIC_PORT_RADIUS = 1.0


def _box(x, y, z, loc=(0, 0, 0), align=None):
    if align is None:
        align = (bd.Align.CENTER, bd.Align.CENTER, bd.Align.MIN)
    return bd.Box(x, y, z, align=align).moved(bd.Location(loc))


def _cylinder(radius, height, loc=(0, 0, 0)):
    return bd.Cylinder(radius, height, align=(bd.Align.CENTER, bd.Align.CENTER, bd.Align.MIN)).moved(bd.Location(loc))


def base_shell():
    # Build the tray from a bottom plate and four closed wall solids. This
    # leaves a real open cavity while keeping the STL as a watertight solid.
    bottom = _box(OUT_X, OUT_Y, WALL)
    front = _box(OUT_X, WALL, BASE_H, loc=(0, OUT_Y / 2 - WALL / 2, 0))
    back = _box(OUT_X, WALL, BASE_H, loc=(0, -OUT_Y / 2 + WALL / 2, 0))
    left = _box(WALL, OUT_Y - 2 * WALL, BASE_H, loc=(-OUT_X / 2 + WALL / 2, 0, 0))
    right = _box(WALL, OUT_Y - 2 * WALL, BASE_H, loc=(OUT_X / 2 - WALL / 2, 0, 0))
    body = bottom + front + back + left + right

    # Small acoustic port for the INMP441. The microphone location is kept
    # adjustable because the breakout's seller-specific placement is not
    # published; keep the port away from the speaker opening and use foam as
    # an acoustic baffle if needed.
    mic_port = bd.Cylinder(MIC_PORT_RADIUS, 4.0,
                           align=(bd.Align.CENTER, bd.Align.CENTER, bd.Align.MIN))
    mic_port = mic_port.rotate(bd.Axis.X, 90).moved(
        bd.Location((MIC_PORT_X, OUT_Y / 2 + 2.0, MIC_PORT_Z)))
    body = body - mic_port

    # A speaker this size cannot fit behind an 18 mm-high front grille. It is
    # therefore mounted face-up under the lid, where the 54 x 76 mm top face
    # provides a top-facing acoustic opening.
    # Battery, microphone and amplifier use removable foam/strap retention in
    # the open cavity. Their seller-specific hole patterns are not published,
    # so hard-coded bosses here would reduce fit tolerance rather than improve it.
    body.label = "base_shell"
    return body


def lid_shell():
    outer = _box(OUT_X, OUT_Y, LID_H, loc=(0, 0, LID_Z))
    # Lid is an open-bottom cap with a 2.4 mm top.
    inner_h = LID_H - WALL + 0.2
    inner = _box(OUT_X - 2 * WALL + FIT_CLEARANCE,
                 OUT_Y - 2 * WALL + FIT_CLEARANCE,
                 inner_h,
                 loc=(0, 0, LID_Z - 0.2))
    body = outer - inner

    # Front camera window. The actual lens board is adjustable by CAM_OPEN_X/CAM_OPEN_Z.
    camera_window = _box(CAM_OPEN_X, 4.0, CAM_OPEN_Z,
                         loc=(0, OUT_Y / 2 - 1.8, LID_Z + 5.0),
                         align=(bd.Align.CENTER, bd.Align.CENTER, bd.Align.CENTER))
    body = body - camera_window

    # Ø34 mm acoustic opening through the lid top. The 40 mm speaker frame
    # overlaps this opening by 3 mm on every side and is retained with foam,
    # adhesive, or a strap after the received speaker thickness is measured.
    speaker_hole = bd.Cylinder(SPEAKER_OPEN_RADIUS, 4.0,
                               align=(bd.Align.CENTER, bd.Align.CENTER, bd.Align.MIN))
    # Start the cutter below the inner ceiling. Starting it at the outer top
    # would leave a 0.4 mm membrane (30 - 27.6 - 2.0) under the opening.
    speaker_hole = speaker_hole.moved(bd.Location((SPEAKER_CENTER_X,
                                                    SPEAKER_CENTER_Y,
                                                    LID_Z + LID_H - WALL - 0.2)))
    body = body - speaker_hole

    # Left-side USB-C service cutout; leaves the board connector accessible.
    # The cut is deliberately kept away from the top and bottom edges to avoid
    # a thin sliver that is difficult to print reliably.
    usb_cutout = _box(4.0, 12.0, 5.0,
                      loc=(-OUT_X / 2 + 1.8, 0.0, LID_Z + 5.0),
                      align=(bd.Align.CENTER, bd.Align.CENTER, bd.Align.CENTER))
    body = body - usb_cutout

    # There are intentionally no screw holes or printed posts in this revision:
    # the seller-specific board positions are not published. Close the lid by
    # friction fit plus foam/adhesive or a soft strap; add fastener datums only
    # after the received parts have been measured.
    body.label = "lid_shell"
    return body


def enclosure_assembly():
    base = base_shell()
    lid = lid_shell()
    base.label = "base_shell"
    lid.label = "lid_shell"
    return bd.Compound(children=[base, lid], label="esp32_voice_cam_enclosure")