Tool/model for laying out a merged front panel

[scottbez1]

combined_front_panel.scad is a model for a configurable merged front panel. The frame width/height are configurable, as are the number of rows & columns of modules and the spacing between modules (can be defined as a "gap" value beyond the minimum possible module spacing, or a center-to-center distance).

There is a matching python script generate_combined_front_panel.py for exporting the design as an SVG, for use with a laser cutter or CAM tool.

Also adds some minimal support for routers/endmills with non-trivial kerf - only for the tabs on the front panel - which adds the option of dog bones for the corners and allows for using a tool that is larger than thickness while still keeping the vertical mounting position constrained.

Example model rendering for a large (4'x8') layout with 108 modules:

[dmadison]

Wow. That's a heck of a panel.

Re: the dog bones, shouldn't the corners of the front window also have those corner drills?

[scottbez1]

The front window doesn't need dog bones since nothing square needs to fit into the corners like for the tab slots.

In my infinite wisdom (or more accurately, because I was copying the CR80 card spec) the flaps were designed with ~3mm radius corners on them, so unless you're using a pretty big tool, the curved corners will function just fine. I'm using a 1/8" diameter end mill, so there's plenty of corner clearance. A 1/4" tool would probably be ok too, but maybe pushing it, though you do need to use a smaller tool at some point for the M4 holes regardless, at which point you might as well use that tool to clean up the window corners too.

[dmadison]

Ah I see. Somehow I had forgotten about the rounded corners on the flaps.