$fn = 64;

// --- Parameters ---
card_width = 66;       // 63mm standard + 3mm for clearance/sleeves
card_length = 91;      // 88mm standard + 3mm for clearance/sleeves
tray_height = 30;      // Overall height of the tray
wall_thickness = 2.5;  // Thickness of the outer walls
base_thickness = 2;    // Thickness of the bottom base
stack_lip_height = 3;  // Height of the interlocking bottom lip
tolerance = 0.5;       // Clearance for stackability

// Calculated outer dimensions
outer_w = card_width + (wall_thickness * 2);
outer_l = card_length + (wall_thickness * 2);

module modular_card_tray() {
    difference() {
        union() {
            // Main outer body
            translate([0, 0, 0])
                linear_extrude(tray_height)
                square([outer_w, outer_l], center=true);
            
            // Bottom stacking lip (male interlocking part)
            // Extends slightly into the main body for a manifold union
            translate([0, 0, -stack_lip_height])
                linear_extrude(stack_lip_height + 0.01)
                square([card_width - tolerance, card_length - tolerance], center=true);
        }
        
        // Inner card cavity
        translate([0, 0, base_thickness])
            linear_extrude(tray_height + 1)
            square([card_width, card_length], center=true);
        
        // Angled side cutouts for easy card retrieval (Long sides)
        hull() {
            translate([0, 0, tray_height + 1])
                cube([outer_w + 2, card_length * 0.85, 0.1], center=true);
            translate([0, 0, base_thickness + 5])
                cube([outer_w + 2, card_length * 0.35, 0.1], center=true);
        }
        
        // Angled thumb cutouts (Short sides)
        hull() {
            translate([0, 0, tray_height + 1])
                cube([card_width * 0.6, outer_l + 2, 0.1], center=true);
            translate([0, 0, base_thickness + 12])
                cube([card_width * 0.25, outer_l + 2, 0.1], center=true);
        }
    }
}

// Render the model
modular_card_tray();