coffee_box.py

import cadquery as cq
from ocp_vscode import show_object

box_length = 180.0
box_width = 120.0
box_height = 60.0
bottom_thickness = 5.0
side_wall_thickness = 10.0  # Double the bottom thickness
fillet_size = 5.0

# Create the outer solid box, centered at the origin
outer_box = cq.Workplane("XY").box(box_length, box_width, box_height)

# Apply fillet to all vertical edges
outer_box = outer_box.edges("|Z").fillet(fillet_size)

# Dimensions for the inner box to be subtracted
inner_length = box_length - (2 * side_wall_thickness)
inner_width = box_width - (2 * side_wall_thickness)
inner_height = box_height - bottom_thickness

# The inner box needs to be shifted upwards so that it doesn't cut through the bottom.
# The top of the inner box should align with the top of the outer box.
z_shift = bottom_thickness / 2

# Create the inner box, shifted up
inner_box = (
    cq.Workplane("XY")
    .workplane(offset=z_shift)
    .box(inner_length, inner_width, inner_height)
    .edges("|Z")
    .fillet(fillet_size)
    .faces("<Z")
    .edges()
    .fillet(fillet_size)
)

open_box = outer_box.cut(inner_box)

# Add cutouts for the knock box bar
bar_diameter = 25.0
bar_radius = bar_diameter / 2
# Position from the front edge of the box
bar_offset_from_front = 60.0

cutter_x = (box_length / 2) - bar_offset_from_front

# To have the top of the bar flush with the top of the box,
# the center of the bar must be lowered by its radius from the top edge.
cutter_z = (box_height / 2) - bar_radius

# Create a cylinder for the round part of the cut, centered at the origin
cutter_cyl = cq.Workplane("XZ").circle(bar_radius).extrude(box_width + 40, both=True)

# Create a rectangular box to clear the material above the cylinder,
# making it a U-shaped slot.
clearance_box = cq.Workplane("XY").box(bar_diameter, box_width + 40, bar_radius)

# Combine them into a single cutter shape.
# The clearance box is positioned so its bottom is at the cylinder's centerline.
cutter = cutter_cyl.union(clearance_box.translate((0, 0, bar_radius / 2)))

# Translate the combined cutter to the final position
cutter = cutter.translate((cutter_x, 0, cutter_z))

# Subtract the cutter from the box
final_box = open_box.cut(cutter)

# Add a swoop down on the front face for hand clearance
swoop_width = 90.0
flat_width = 40.0
swoop_depth = 20.0
h = box_height / 2

final_box = (
    final_box.faces(">X")
    .workplane()
    .moveTo(-swoop_width / 2, h)
    .spline(
        [
            (-flat_width / 2, h - swoop_depth),
            (flat_width / 2, h - swoop_depth),
            (swoop_width / 2, h),
        ],
        tangents=[(1, 0), (1, 0), (1, 0), (1, 0)],
        includeCurrent=True,
    )
    .lineTo(swoop_width / 2, h + 1)
    .lineTo(-swoop_width / 2, h + 1)
    .close()
    .cutBlind(-side_wall_thickness)
)

# Fillet top edges (rim and swoop) but exclude the knock bar cutouts
final_box = final_box.edges(
    cq.selectors.BoxSelector(
        (
            cutter_x + bar_radius + 0.1,
            -box_width / 2 - 1,
            box_height / 2 - swoop_depth - 1,
        ),
        (box_length / 2 + 1, box_width / 2 + 1, box_height / 2 + 1),
    )
    + cq.selectors.BoxSelector(
        (-box_length / 2 - 1, -box_width / 2 - 1, box_height / 2 - swoop_depth - 1),
        (cutter_x - bar_radius - 0.1, box_width / 2 + 1, box_height / 2 + 1),
    )
).fillet(2.0)

# Add embossed text "Baulsupp Design" on the back external face.
final_box = (
    final_box.faces("<X")
    .workplane(centerOption="CenterOfBoundBox")
    .text("Baülsupp Design", 12, -1.0, fontPath="AlbertSans.ttf")
)

show_object(final_box)

cq.exporters.export(final_box, "coffee_box.stl")