$fn = 64;

// --- Parameters ---
hex_size = 20;        // Flat-to-flat distance for standard hex wall (e.g., HSW)
tolerance = 0.2;      // Tolerance for a snug fit
hex_depth = 8;        // Depth of the hex plug

front_width = 60;     // Width of the front earbud holder plate
front_height = 32;    // Height of the front plate
front_thickness = 10; // Thickness of the front plate

spool_radius = 8;     // Radius of the cable wrap spool
spool_height = 15;    // Height of the cable wrap area

base_radius = 20;     // Radius of the back plate
base_thickness = 3;   // Thickness of the back plate

cavity_radius = 8.5;  // Radius of the earbud head cavity
stem_radius = 4.5;    // Radius of the earbud stem cavity
cavity_depth = 8;     // Depth of the earbud cavities
slot_width = 3;       // Width of the wire slot

// --- Derived Values ---
hex_r = ((hex_size - tolerance) / 2) / cos(30);
chamfer_height = base_radius - spool_radius;

// --- Modules ---
module pill(w, h, d) {
    hull() {
        translate([-w/2 + h/2, 0, 0]) cylinder(r=h/2, h=d);
        translate([w/2 - h/2, 0, 0]) cylinder(r=h/2, h=d);
    }
}

// --- Main Model ---
// Designed to print face-down (Z=0 on the build plate) without supports
difference() {
    union() {
        // Front Plate
        pill(front_width, front_height, front_thickness);

        // Central Spool
        translate([0, 0, front_thickness])
            cylinder(r=spool_radius, h=spool_height);

        // 45-degree Chamfer (Support-free bridge to base plate)
        translate([0, 0, front_thickness + spool_height])
            cylinder(r1=spool_radius, r2=base_radius, h=chamfer_height);

        // Base Plate
        translate([0, 0, front_thickness + spool_height + chamfer_height])
            cylinder(r=base_radius, h=base_thickness);

        // Hex Plug (Rotated 30 deg for standard vertical orientation)
        translate([0, 0, front_thickness + spool_height + chamfer_height + base_thickness])
            rotate([0, 0, 30])
            union() {
                cylinder(r=hex_r, h=hex_depth - 1, $fn=6);
                translate([0, 0, hex_depth - 1])
                    cylinder(r1=hex_r, r2=hex_r - 1, h=1, $fn=6);
            }
    }

    // Left Earbud Cavity & Slot
    hull() {
        translate([-15, 3, -1]) cylinder(r=cavity_radius, h=cavity_depth + 1);
        translate([-15, -8, -1]) cylinder(r=stem_radius, h=cavity_depth + 1);
    }
    translate([-15 - slot_width/2, -front_height/2 - 1, -1])
        cube([slot_width, front_height/2, front_thickness + 2]);

    // Right Earbud Cavity & Slot
    hull() {
        translate([15, 3, -1]) cylinder(r=cavity_radius, h=cavity_depth + 1);
        translate([15, -8, -1]) cylinder(r=stem_radius, h=cavity_depth + 1);
    }
    translate([15 - slot_width/2, -front_height/2 - 1, -1])
        cube([slot_width, front_height/2, front_thickness + 2]);
}