// // Spherical Harmonics Ear Project (*SpHEAR) // // Octathingy, Second Order Ambisonics Microphone // // based on: // "A second-order soundfield microphone with improved polar pattern shape" // by Eric Benjamin, Audio Engineering Society Convention Paper 8728, // October 2012, San Francisco // // Copyright 2015-2016, Fernando Lopez-Lezcano, All Rights Reserved // nando@ccrma.stanford.edu // // This program is free software: you can redistribute it and/or modify // it under the terms of the GNU General Public License as published by // the Free Software Foundation, either version 3 of the License, or // (at your option) any later version. // // This program is distributed in the hope that it will be useful, // but WITHOUT ANY WARRANTY; without even the implied warranty of // MERCHANTABILITY or FITNESS FOR A PARTICULAR PURPOSE. See the // GNU General Public License for more details. // // You should have received a copy of the GNU General Public License // along with this program. If not, see . // // 3d Models released under the Creative Commons license as follows: // Attribution-NonCommercial-ShareAlike 4.0 International (CC BY-NC-SA 4.0) // http://creativecommons.org/licenses/by-nc-sa/4.0/ include ; include ; include ; //// //// overrides mount_radius = 5; //// //// default model parameters //// // size of Zapnspark printed circuit board // kicad length = 79.375 // measured length = 79.20 (2016.08.25) pcb_length = 79.20; // kicad width = 19.050 // measured width = 18.82 (2016.08.25) pcb_width = 18.85; // ultimaker spec thickness = 1.61 // measured thickness = 1.56 (w/ copper) pcb_thickness = 1.58; // tolerance to add to length and width of pcb // // measured 3d print width = 18.70 (with pcb_fit = 0.3) // actual printed = 18.70 - 0.3 = 16.97 // total correction = 18.85 - 16.97 = 1.88 // pcb_fit = 0.4; // tolerance add to thickness of pcb // // printed with pcb_tfit = 0.15 -> 1.58 + 0.15 = 1.73 (ideal printed) // measured print channel = 1.63 : 0.1 thinner (ultimaker 2 plus, 2016.08.24) // measured pcb thickness = 1.58 (othermill) // pcb_tfit = 0.15; // we leave part of the pcb exposed on the bottom of the body so that we // can solder the wires that connect the microphone with the // preamplifier, same at the top of the pcb to solder the wires // to the capsules pcb_low_exp = 12.0; pcb_hi_exp = 8.0; // lip fit for flares lip_fit = 0.15; // clearance from the bottom and top of pcb's to the start of the flare, // this adds space for the protuding molex pins on which we solder pcb_low_clear = 15.0; pcb_hi_clear = 15.0; // depth of slot into which the printed circuit board fits pcb_slot_depth = 1.0; // diameter of four conductor cable cable_diam = 9.5; // lip that mounts flares into main body box mount_lip = 6.0; // capsule array mount, height of flare and stalk flare_height = 50; stalk_height = 60; // wall thickness wall = 1.0; // back and front clearance of pcb (components and leads) pcb_front = 13.25; pcb_back = 3.0; // calculated minimum "radius" of microphone box box_radius = pcb_front + (pcb_thickness + pcb_tfit) + pcb_back + 2 * wall; // calculated main body corner radius mount_corner = box_radius - pcb_width / 2 + pcb_slot_depth + 1.0; // shock mount parameters // ring_sep = 30.0; ring_height = 10.0; rubber_band_angle = 40; main_radius_inc = (ring_sep / 2) / tan(rubber_band_angle); // gap between internal ring and microphone body internal_ring_gap = 1.0; // connector that joins the two internal rings connector_w = 10.0; connector_d = 2.0; // the printed circuit board module pcb(length, width, thick) { translate([-width/2, 0, 0]) { cube([width, thick, length]); } } // the printed circuit board plus space in the front and back for components module pcb_clear(length, width, thick, slot_depth, front, back) { translate([0, - (thick + front)]) { pcb(length, width, thick); // clear space in the front translate([- (width/2 - slot_depth), thick, 0]) { cube([width - 2 * slot_depth, front, length]); } // clear space in the back translate([- (width/2 - slot_depth), - back, 0]) { cube([width - 2 * slot_depth, back, length]); } } } // all eight printed circuit boards module octa_pcb_clear(length, width, thick, slot_depth, front, back) { for (ytrans = [-1, 1]) { translate([0, ytrans * (front + back + thick), 0]) { for (rot = [0, 90, 180, 270]) { rotate([0, 0, rot]) { pcb_clear(pcb_length + pcb_fit, pcb_width + pcb_fit, pcb_thickness + pcb_tfit, slot_depth, front, back); } } } } } // box with rounded corners module solid_round_box(height, width, depth, radius) { dw = width - radius; dd = depth - radius; minkowski() { translate([-dw, -dd, 0]) { cube([dw * 2, dd * 2, height / 2]); } cylinder(r = radius, h = height / 2, $fn = facets); } } module round_box(height, width, depth, radius, wall) { iradius = radius * ((width - wall) / width); difference() { solid_round_box(height, width, depth, radius); solid_round_box(height, width - wall, depth - wall, iradius); } } module octa_mount_box(height, xr, yr, corner) { xrd = xr - corner; yrd = yr - corner; minkowski() { translate([-xrd, -yrd, 0]) { cube([xrd * 2, yrd * 2, height / 2]); } cylinder(r = corner, h = height / 2, $fn = facets); } } // inset box with rounded corners module octa_mount_box_relative(height, ref_xradius, ref_yradius, ref_corner, radius_inc) { corner = ref_corner * ((ref_xradius + radius_inc) / ref_xradius); octa_mount_box(height, ref_xradius + radius_inc, ref_yradius + radius_inc, corner); } // the main body of the microphone mount module octa_mount_body(height, width, depth, radius, lower_lip, upper_lip, clear) { // outer shell difference() { round_box(height, width, depth, radius, 2 * wall); // upper lip for flare to microphone translate([0, 0, height - upper_lip]) { round_box(upper_lip, width, depth, radius, wall + lip_fit); } // lower lip for flare to cable translate([0, 0, 0]) { round_box(upper_lip, width, depth, radius, wall + lip_fit); } } // mounting slots for pcb's slot_len = 30; difference() { solid_round_box(slot_len, width - wall - lip_fit, depth - wall - lip_fit, radius); union() { // hollow out the inside with slots for pcbs octa_pcb_clear(slot_len, pcb_width, pcb_thickness, pcb_slot_depth, pcb_front, pcb_back); // trim square angles for (ytrans = [-1, 1]) { translate([0, ytrans * (pcb_front + pcb_back + pcb_thickness), 0]) { cylinder(r = pcb_front + pcb_thickness, h = height, $fn = facets); } } } } // add parts for clearance check if (clear == 1) { // electrolytic capacitors cap_diam = 10.2; for (rot = [0, 180, 270]) { rotate([0, 0, rot]) { translate([-pcb_front + cap_diam/2, 0, 0]) { *cylinder(r = (cap_diam/2), h = 20, $fn = facets); } } } // PCBs for (rot = [0, 180, 270]) { rotate([0, 0, rot]) { translate([-(pcb_front + pcb_thickness), -pcb_width/2, -pcb_low_exp]) { cube([pcb_thickness, pcb_width, pcb_length]); } } } // connectors cap_h = 12.3; cap_w = 10.53/2; for (rot = [0, 180, 270]) { rotate([0, 0, rot]) { translate([-pcb_front, -cap_w/2 - 2.5, 0]) { *cube([cap_h, cap_w, 20]); } } } } } // flares from the body to the microphone stalk and cable module octa_mount_flare(height, lip, transition, xradius, yradius, corner, top_radius, stalk_height, dot) { // bottom rounded box difference() { octa_mount_box(height, xradius, yradius, corner); octa_mount_box_relative(height, xradius, yradius, corner, -(2 * wall)); // flange to mount on body octa_mount_box_relative(lip + 1.00, xradius, yradius, corner, - (wall)); } // flare to round section translate([0, 0, height]) { difference() { hull() { octa_mount_box(1, xradius, yradius, corner); translate([0, 0, transition]) { cylinder(r = top_radius, h = 1, $fn = facets); } } hull() { octa_mount_box_relative(1, xradius, yradius, corner, - 2 * wall); translate([0, 0, transition]) { cylinder(r = top_radius - wall, h = 1, $fn = facets); } } } } // cylindrical stalk translate([0, 0, height + transition]) { difference() { cylinder(r = top_radius, h = stalk_height, $fn = facets); cylinder(r = top_radius - wall, h = stalk_height, $fn = facets); } // add marker for "back of microphone" orientation if (dot == 1) { rotate([0, 0, 90]) { translate([0, top_radius - wall * 2 / 3, stalk_height - top_radius]) { difference() { sphere(r = top_radius / 3, $fn = 32); translate([0, -top_radius + top_radius / 2, 0]) { cube([top_radius, top_radius, top_radius], center = true); } } } } } } } // flares from the body to a dual cable housing module octa_mount_flare_dual(height, lip, transition, xradius, yradius, corner, top_radius, stalk_height) { // hack to get it to render, fix problem in octa_mount_box when radius is equal to corner... delta = 0.001; // bottom rounded box difference() { octa_mount_box(height, xradius, yradius, corner); octa_mount_box_relative(height, xradius, yradius, corner, -(2 * wall)); // flange to mount on body octa_mount_box_relative(lip + 1.00, xradius, yradius, corner, - (wall)); } // flare to rounded section section translate([0, 0, height]) { difference() { hull() { octa_mount_box(0.01, xradius, yradius, corner); translate([0, 0, transition]) { octa_mount_box(0.01, top_radius, top_radius * 2, top_radius - delta); } } hull() { octa_mount_box_relative(0.01, xradius, yradius, corner, - 2 * wall); translate([0, 0, transition]) { octa_mount_box(0.01, top_radius - wall, (top_radius * 2) - 1.5 * wall, top_radius - wall - delta); } } } } // corner box cable stalk translate([0, 0, height + transition]) { difference() { octa_mount_box(stalk_height, top_radius, top_radius * 2, top_radius - delta); // add holes for two cables for (offset = [top_radius - wall/2, -(top_radius - wall/2)]) { translate([0, offset, 0]){ cylinder(r = top_radius - wall, h = stalk_height, $fn = facets); } } } } } // top conical section that plugs into capsule array module octa_capsule_array_mount(angles) { difference() { translate([0, 0, 0]) { rotate([0, 0, 45]) { difference() { cylinder(h = mount_top_height, r1 = mount_radius + wall, r2 = mount_radius_capsule, $fn = facets); cylinder(h = mount_top_height, r1 = mount_radius, r2 = mount_radius_capsule * 0.8, $fn = facets); } } } // indentations that match the four lower capsule holders // add ridge height adjustment translate([0, 0, mount_top_height + (mic_radius - capsule_height) + capsule_height * cos(90 - elev_angle) - 2]) { for (az = angles) { rotate([0, 180 - elev_angle, az + 45]) { translate([0, 0, mic_radius - capsule_height]) { capsule(leg_angles, 0, 1, ridge_wfit, ridge_hfit, 1); } } } } // indentations at the top to open up the array a bit echo (mount_radius_capsule); translate([0, 0, mount_top_height + mount_radius_capsule / 8]) { for (rot = [45, 135, -135, -45]) { translate([0, 0, 0]) { rotate([0, 90, rot]) { linear_extrude(height = mount_radius * 2.0) { minkowski() { polygon(points = [[0, mount_radius_capsule * 0.35], [0, - mount_radius_capsule * 0.35], [mount_radius_capsule * 2 / 3, 0]]); circle(r = 1.0, $fn = facets); } } } } } } } } // internal ring of shock mount module tetra_shock_mount_internal_ring(height, radius, corner, gap, lip) { slot_sep = radius * 2 / 2.5; slot_w = 5; slot_o = height / 3; difference() { union() { // base ring difference() { tetra_mount_box_relative(slot_o, radius + gap, corner, 3 * wall); tetra_mount_box(slot_o, radius + gap, corner); } // upper ring with slots for rubber bands difference() { tetra_mount_box_relative(height, radius + gap + 2 * wall, corner, 2 * wall); tetra_mount_box_relative(height, radius + gap + wall, corner, 1 * wall); for (rot = [0, 90, 180, 270]) rotate([0, 0, rot]) { // slots for rubber bands minkr = 1.25; for (m = [0, 1]) mirror([0, m, 0]) { translate([-slot_w / 2 + slot_sep, radius + gap, slot_o + minkr]) { minkowski() { cube([slot_w - minkr, 10, slot_o - minkr]); rotate([90, 0, 0]) cylinder(r = minkr, h = 1, $fn = facets); } translate([slot_w / 2, -2, 0]) { cube([slot_w / 2, 10, 10]); } } } } } // body for bars that connect both rings together for (rot = [0, 90, 180, 270]) rotate([0, 0, rot]) { translate([radius + gap + 3 * wall, -(connector_w/2 + wall), 0]) { cube([connector_d + wall, connector_w + 2 * wall, height]); } for (m = [0, 1]) mirror([0, m, 0]) { translate([radius + gap + 4 * wall, -(connector_w/2 + wall), 0]) { cylinder(r = wall * 2, h = height, $fn = 3); } } } } // carve holes for bars that connect both rings for (rot = [0, 90, 180, 270]) rotate([0, 0, rot]) { translate([radius + gap + 3 * wall, -connector_w/2, 0]) { cube([connector_d, connector_w, height - 2.75 * wall]); translate([connector_d / 2, 0, height - 3 * wall]) { rotate([-90, 0, 0]) { cylinder(r = connector_d / 2, h = connector_w, $fn = facets); } } } } } for (rot = [0, 90, 180, 270]) rotate([0, 0, rot]) { // lip to support microphone on lower ring only if (lip == 1) { lip_w = 10; translate([radius + gap + 2.5 * wall, -lip_w/2, height]) { rotate([90, 90, 180]) { linear_extrude(height = lip_w) { polygon([[0, 0], [0, 4], [1, 4], [height * 2/3, 0]]); } } } } } } // eyelet for connecting the external ring to the stand mount module tetra_shock_mount_ring(outside_radius, inside_radius, thickness) { difference() { union() { cylinder(r = outside_radius, h = thickness, $fn = facets); translate([0, -outside_radius, 0]) { cube([outside_radius, outside_radius, thickness]); } } cylinder(r = inside_radius, h = thickness, $fn = facets); } } // external ring of shock mount (connects to stand mount) module tetra_shock_mount_external_ring(height, radius, corner, gap, lip) { difference() { tetra_mount_box_relative(6, radius, mount_corner, gap); tetra_mount_box_relative(6, radius, mount_corner, gap - 4 * wall); } for (rot = [0, 90, 180, 270]) { rotate([0, 0, rot]) { translate([radius + gap + 4 * wall, -7.5, 0]) { cube([4, 15, 6]); } translate([radius + gap, -2, 0]) { cube([7, 4, 6]); } } } // connection to stand mount translate([0, 18, 0]) { intersection() { difference() { tetra_mount_box_relative(6, radius, mount_corner - 5, gap); tetra_mount_box_relative(6, radius, mount_corner - 5, gap - 4 * wall); } translate([-(radius + 2 * mount_corner), 0, 0]) { cube([2 * (radius + 2 * mount_corner), radius + 2 * mount_corner, 6]); } } } // connection to hub translate([-2, radius + 2 * mount_corner + 12, 0]) { cube([4, 10, 6]); } // rotating mount o_rad = 8; i_rad = 3; thk = 4; rotate([0, 90, 0]) { translate([-o_rad, 66, -2]) { tetra_shock_mount_ring(o_rad, i_rad, thk); } } } // connector that joins the two internal rings module tetra_shock_mount_connector(length, lip, width, thickness, fit) { cube([length + 2 * lip , width - 2 * fit, thickness - 2 * fit]); translate([lip, -(thickness / 2), 0]) cube([length , width + thickness, thickness * 3 / 2]); } // mount to standard microphone clip stand mount module tetra_shock_mount_stand(height, wall, stand_wall) { // stand mount translate([0, 0, 0]) { difference() { union() { // main mount cylinder translate([0, 0, 0]) { difference() { cylinder(r = mic_mount_radius + mic_mount_fit + stand_wall, h = height, $fn = facets); // make the hole for the mount (* 1.5 to cut the ridge as well) cylinder(r = mic_mount_radius + mic_mount_fit, h = height, $fn = facets); } } } // slot for fitting into microphone stand translate([mic_mount_radius - stand_wall / 2, - mic_mount_slot_width / 2, 0]) { cube([2 * stand_wall, mic_mount_slot_width, mic_mount_slot_height]); } // eyelet for microphone stand translate([mic_mount_radius - stand_wall / 2, 0, mic_mount_slot_height]) { rotate([0, 90, 0]) { cylinder(r = mic_mount_slot_radius, h = 2 * stand_wall, $fn = facets); } } } // top of mount translate([0, 0, height]) { difference() { cylinder(h = mic_mount_radius, r1 = mic_mount_radius + mount_wall + wall + mic_mount_fit, r2 = 5, $fn = facets); cylinder(h = mic_mount_radius, r1 = mic_mount_radius + mount_wall + mic_mount_fit, r2 = 1, $fn = facets); } translate([0, 0, mic_mount_radius - 1]) { cylinder(h = 1, r = 5, $fn = facets); } } // eyelets o_rad = 8; i_rad = 3; thk = 4; for (m = [0, 1]) mirror([0, m, 0]) { rotate([90, 90, 0]) { translate([-(height + o_rad + 6), 0, thk/2 + fit]) { rotate([0, 0, 45]) tetra_shock_mount_ring(o_rad, i_rad, thk); } } } } } //// //// render all the different parts //// // microphone body: flare to capsule array (slips into PCB holder body) // module render_octa_capsule_flare(z_offset) { translate([0, 0, z_offset]) { octa_mount_flare(pcb_hi_clear + pcb_hi_exp, mount_lip, flare_height, box_radius + wall, box_radius * 2 - wall, mount_corner, mount_radius + wall, stalk_height, 1); translate([0, 0, pcb_hi_clear + pcb_hi_exp + flare_height + stalk_height]) { octa_capsule_array_mount([45, 135, -45, -135]); } } } // microphone body: main body, holds printed circuit boards // octa_pcb_mount_height = pcb_length - pcb_low_exp - pcb_hi_exp; module render_octa_pcb_mount(z_offset, showint) { translate([0, 0, z_offset]) { octa_mount_body(octa_pcb_mount_height, box_radius + wall, box_radius * 2 - wall, mount_corner, mount_lip, mount_lip, 0); } // add ccrma logo rotate([0, 0, -90]) { translate([0, -(box_radius - 0.5), octa_pcb_mount_height / 2]) { rotate([90, 270, 0]) { logo_scale = 1 / 2.2; scale([logo_scale, logo_scale, 1.0]) { ccrma_logo(1.65); } } } } } // microphone body: flare to microphone cable (slips into PCB holder body) // module render_octa_cable_flare(z_offset, flip) { translate([0, 0, z_offset]) { octa_mount_flare_dual(pcb_low_clear + pcb_low_exp, mount_lip, 20, box_radius + wall, box_radius * 2 - wall, mount_corner, cable_diam / 2 + wall, 10, 0); } } // microphone body: render all parts with a vertical separation // module render_octa_body(z_offset, spread, showint) { rotate([0, 180, 0]) { render_octa_cable_flare(0); } lippy = spread - mount_lip; render_octa_pcb_mount(lippy, showint); render_octa_capsule_flare(octa_pcb_mount_height + 2 * lippy); } // microphone: render the full assembly with a vertical separation // module render_octa_microphone(z_offset, spread) { render_octa_body(z_offset, spread); lippy = spread - mount_lip; render_octa_capsule_array(z_offset + octa_pcb_mount_height + mount_top_height + flare_height + stalk_height + pcb_hi_clear + pcb_hi_exp + 2 * lippy + spread + mic_radius); } // microphone: render the full assembly with a vertical separation // cut out halt of the assembly so that we can see the inside // module render_octa_microphone_cutout(z_offset, spread) { difference() { render_octa_microphone(z_offset, spread); // a cube that blots out 1/4 of the microphone rotate([0, 0, 45]) { translate([0, 0, -50]) { cube([50, 100, 650]); } } } } // shock mount: microphone clip on stand mount // module render_tetra_shock_mount_stand(z_offset) { translate([z_offset]) { tetra_shock_mount_stand(mic_mount_height, mount_wall, mic_mount_wall); } } // shock mount: external ring // module render_tetra_shock_mount_external_ring(z_offset) { translate([0, 0, z_offset]) { tetra_shock_mount_external_ring(ring_height, box_radius + wall, mount_corner, main_radius_inc, 0); } } // shock mount: bottom internal ring // module render_tetra_shock_mount_internal_ring_bot(z_offset) { translate([0, 0, z_offset]) { tetra_shock_mount_internal_ring(ring_height, box_radius + wall, mount_corner, internal_ring_gap, 1); } } // shock mount: all four internal ring connectors // module render_tetra_shock_mount_ring_connectors(offset) { for (o = [0, 1, 2, 3]) { translate([-18, (10 + offset) * o, 0]) { tetra_shock_mount_connector(ring_sep, 4, connector_w, connector_d, 0.1); } } } // shock mount: top internal ring // module render_tetra_shock_mount_internal_ring_top(z_offset) { translate([0, 0, z_offset]) { tetra_shock_mount_internal_ring(ring_height, box_radius + wall, mount_corner, internal_ring_gap, 0); } } // shock mount: render all parts // module render_tetra_shock_mount(z_offset) { // internal rings translate([0, 0, z_offset + ring_sep / 2]) { render_tetra_shock_mount_internal_ring_top(0); rotate([0, 180, 0]) { render_tetra_shock_mount_internal_ring_bot(ring_sep + 2); } // insert the connecting rods for (r = [0, 90, 180, 270]) { rotate([0, 0, r]) { translate([box_radius + 3 * wall + internal_ring_gap, 0, -1]) { rotate([0, 90, 0]) { translate([-4, -5, 1]) { tetra_shock_mount_connector(ring_sep, 4, connector_w, connector_d, 0.1); } } } } } } // external ring translate([0, 0, z_offset - ring_height / 4]) { render_tetra_shock_mount_external_ring(0); } // mount to stand translate([0, 85, -(mic_mount_height + mic_mount_radius + ring_height / 4)]) { rotate([0, 0, 90]) { render_tetra_shock_mount_stand(0); } } }