module rounded_square(dimensions, radius, center=true) { minkowski(){ square(dimensions - 2 * [radius,radius], center=center); circle(radius); } } CASE_WIDTH = 245; CASE_HEIGHT = 92; CASE_THICKNESS = 6.0; SCREW_DIAMETER = 3.0; SCREW_OFFSET = 4; // solution and simplification of // 2*(INNER_RADIUS+CASE_THICKNESS)^2 = (INNER_RADIUS+OUTER_RADIUS+sqrt(2 * SCREW_OFFSET ^ 2))^2 // INNER_RADIUS = sqrt(2) * (2 * SCREW_OFFSET - CASE_THICKNESS) + 3 * SCREW_OFFSET - 2 * CASE_THICKNESS; INNER_RADIUS = (2 + sqrt(2)) * (2 * SCREW_OFFSET - CASE_THICKNESS) - SCREW_OFFSET; echo("INNER_RADIUS=", INNER_RADIUS); difference() { rounded_square([245,92], SCREW_OFFSET); translate([+(CASE_WIDTH/2 - SCREW_OFFSET), +(CASE_HEIGHT/2 - SCREW_OFFSET)]) circle(SCREW_DIAMETER / 2); translate([+(CASE_WIDTH/2 - SCREW_OFFSET), -(CASE_HEIGHT/2 - SCREW_OFFSET)]) circle(SCREW_DIAMETER / 2); translate([-(CASE_WIDTH/2 - SCREW_OFFSET), +(CASE_HEIGHT/2 - SCREW_OFFSET)]) circle(SCREW_DIAMETER / 2); translate([-(CASE_WIDTH/2 - SCREW_OFFSET), -(CASE_HEIGHT/2 - SCREW_OFFSET)]) circle(SCREW_DIAMETER / 2); rounded_square([245 - 2 * CASE_THICKNESS,92 - 2 * CASE_THICKNESS], INNER_RADIUS); }