$fn=64;

/* Parametric Variables */
case_width = 56;       // Width of the earbuds case
case_depth = 24;       // Depth of the earbuds case
case_height = 40;      // Height of the holder pocket
wall_thickness = 3;    // Wall thickness
hex_f2f = 14;          // Hex flat-to-flat distance (HSW compatible standard)
hex_depth = 10;        // Depth of the hex peg
cable_cutout = 15;     // Diameter of bottom charging cable hole
corner_radius = 4;     // Outer corner radius

// Calculated dimensions
outer_w = case_width + wall_thickness * 2;
outer_d = case_depth + wall_thickness * 2;
outer_h = case_height + wall_thickness;

union() {
    // Main Holder Body
    difference() {
        // Outer shape
        rounded_box(outer_w, outer_d, outer_h, corner_radius);

        // Inner cavity
        translate([0, 0, wall_thickness])
            rounded_box(case_width, case_depth, outer_h + 1, corner_radius/2);

        // Front thumb cutout (to easily grab the case)
        translate([0, outer_d/2, outer_h])
            rotate([90, 0, 0])
            cylinder(r=case_width/2.5, h=outer_d, center=true);

        // Bottom cable cutout
        translate([0, 0, -1])
            cylinder(d=cable_cutout, h=wall_thickness + 2);
    }

    // Hex Peg (Back attachment)
    // +0.1 ensures a manifold union with the back wall
    translate([0, -outer_d/2 + 0.1, outer_h - hex_f2f - 5]) {
        rotate([90, 0, 0]) {
            // Main hex peg
            cylinder(r=hex_f2f / sqrt(3), h=hex_depth, $fn=6);
            
            // Standoff / reinforcement collar
            cylinder(r=(hex_f2f / sqrt(3)) + 1.5, h=2);
        }
    }
}

// Helper module for a Z-extruded rounded box
module rounded_box(w, d, h, r) {
    hull() {
        for(x = [-w/2+r, w/2-r]) {
            for(y = [-d/2+r, d/2-r]) {
                translate([x, y, 0])
                    cylinder(r=r, h=h);
            }
        }
    }
}