$fn=64;

// --- Parameters ---
hex_flat_to_flat = 30;     // Flat-to-flat width of a single hex cell (mm)
divider_height = 25;       // Overall height of the divider (mm)
wall_thickness = 1.2;      // Thickness of the divider walls (mm)
snap_bump_depth = 0.6;     // Protrusion of the snap-fit retention bumps (mm)
tolerance = 0.2;           // Clearance tolerance for easy insertion (mm)

// --- Calculated Dimensions ---
hex_radius = hex_flat_to_flat / sqrt(3);
// Radius of a 7-hex cluster (center of middle hex to outer point of outer hex)
total_radius = hex_flat_to_flat + hex_radius - tolerance;

module divider_blade() {
    union() {
        // Main dividing wall
        translate([0, -wall_thickness/2, 0])
            cube([total_radius, wall_thickness, divider_height]);
        
        // Snap-in friction bump on the outer edge
        translate([total_radius - snap_bump_depth - 0.5, 0, divider_height/2])
            cylinder(
                r = wall_thickness/2 + snap_bump_depth, 
                h = divider_height * 0.5, 
                center = true
            );
            
        // Chamfered top/bottom for the snap bump to allow easy insertion
        translate([total_radius - snap_bump_depth - 0.5, 0, divider_height * 0.25])
            sphere(r = wall_thickness/2 + snap_bump_depth);
        translate([total_radius - snap_bump_depth - 0.5, 0, divider_height * 0.75])
            sphere(r = wall_thickness/2 + snap_bump_depth);
    }
}

module snap_in_divider() {
    union() {
        // Generate the 6 radiating walls
        for (i = [0:5]) {
            rotate([0, 0, i * 60])
                divider_blade();
        }
        
        // Central reinforcement hub to ensure manifold geometry at the intersection
        cylinder(r = wall_thickness, h = divider_height);
    }
}

// Render the divider
snap_in_divider();