Cable Conceal Box

/* [Global] */
// Which part to display?
part = "both"; // [both:Both (Preview), wall:Wall Mount Only, cover:Front Cover Only]

// Total outer width
box_width = 80; // [40:5:200]
// Total outer height
box_height = 80; // [40:5:200]
// Total outer depth
box_depth = 30; // [10:5:100]
// Outer corner radius
corner_radius = 12; // [2:1:30]
// Thickness of the walls
wall_thickness = 2; // [1.0:0.1:5.0]
// Gap between parts for fit
clearance = 0.25; // [0.1:0.05:1.0]

/* [Wall Mount Features] */
// Height of the internal mounting walls
mount_wall_height = 15; // [10:1:40]
// Percentage of height the hole takes
hole_ratio = 0.5; // [0.1:0.05:0.8]
// Position of the cable hole
hole_alignment = "sticky"; // [centered:Centered, sticky:Sticky to Wall]

/* [Snap Mechanism] */
// Width of the rectangular snap
detent_width = 15; // [5:1:50]
// Vertical thickness of the snap
detent_thickness = 2.5; // [1:0.1:5]
// Height of the lead-in chamfer (ramp)
detent_chamfer = 1.8; // [0.5:0.1:5]
// Distance from top edge for snap
detent_offset = 6; // [3:1:20]

/* [Hidden] */
$fn = 64;
mount_w = box_width - (wall_thickness * 2) - (clearance * 2);
mount_h = box_height - (wall_thickness * 2) - (clearance * 2);
mount_r = max(1, corner_radius - wall_thickness);
hole_h = mount_h * hole_ratio;
sticky_y = (mount_h / 2) - (hole_h / 2) - (wall_thickness * 1.5);
hole_y = (hole_alignment == "sticky") ? sticky_y : 0;

// Pocket depth (doesn't go all the way through)
pocket_depth = wall_thickness * 0.7;
// Small wiggle room for the pocket
v_clearance = 0.2;

module rounded_rect_ex(w, h, d, r) {
    hull() {
        for (x = [-w/2+r, w/2-r])
        for (y = [-h/2+r, h/2-r])
        translate([x, y, 0]) cylinder(r=r, h=d);
    }
}

// Simple rectangular pocket for the wall mount
module simple_pocket(w, d, h) {
    cube([w + 0.4, d, h + v_clearance], center=true);
}

// The internal bar with a bottom chamfer for the cover
module chamfered_snap_bar() {
    t_prot = wall_thickness * 0.6; // protrusion depth
    hull() {
        // Bottom "edge" (thin start of the ramp)
        translate([0, 0, -detent_thickness/2])
        cube([detent_width, 0.1, 0.1], center=true);
        
        // Top "block" (full thickness)
        translate([0, 0, detent_chamfer/2])
        cube([detent_width, t_prot, detent_thickness - detent_chamfer], center=true);
    }
}

module wall_mount() {
    z_pos = wall_thickness + mount_wall_height - detent_offset;
    difference() {
        union() {
            // Base Plate
            rounded_rect_ex(mount_w, mount_h, wall_thickness, mount_r);
            
            // Upright mounting walls
            translate([0, 0, wall_thickness])
            difference() {
                rounded_rect_ex(mount_w, mount_h, mount_wall_height, mount_r);
                translate([0, 0, -1])
                rounded_rect_ex(mount_w - (wall_thickness*2), mount_h - (wall_thickness*2), mount_wall_height + 2, max(0.1, mount_r - wall_thickness));
            }
        }
        
        // Main Cable Hole
        translate([0, hole_y, -1])
        rounded_rect_ex(mount_w * 0.7, hole_h, wall_thickness + 2, 4);
        
        // 8-slit relief system (for wall flex)
        for(x = [-1, 1]) for(y = [-1, 1]) {
            translate([x * (mount_w/2 - mount_r), y * (mount_h/2 - wall_thickness/2), wall_thickness + mount_wall_height/2])
            cube([1, wall_thickness + 1, mount_wall_height + 1], center=true);
            translate([x * (mount_w/2 - wall_thickness/2), y * (mount_h/2 - mount_r), wall_thickness + mount_wall_height/2])
            cube([wall_thickness + 1, 1, mount_wall_height + 1], center=true);
        }
        
        // Rectangular Blind Pockets on all 4 walls
        for(y = [-1, 1]) translate([0, y * (mount_h/2 - wall_thickness/2 + pocket_depth/2), z_pos]) 
            simple_pocket(detent_width, pocket_depth, detent_thickness);
            
        for(x = [-1, 1]) translate([x * (mount_w/2 - wall_thickness/2 + pocket_depth/2), 0, z_pos]) 
            rotate([0, 0, 90]) simple_pocket(detent_width, pocket_depth, detent_thickness);
    }
}

module front_cover() {
    z_pos = wall_thickness + mount_wall_height - detent_offset;
    difference() {
        rounded_rect_ex(box_width, box_height, box_depth, corner_radius);
        translate([0, 0, -1])
        rounded_rect_ex(box_width - (wall_thickness*2), box_height - (wall_thickness*2), box_depth - wall_thickness + 1, max(0.1, corner_radius - wall_thickness));
    }
    
    // Internal Detent Bars with Bottom Chamfer
    for(y = [-1, 1]) translate([0, y * (box_height/2 - wall_thickness - clearance/2), z_pos]) 
        rotate([0, 0, (y > 0) ? 180 : 0]) chamfered_snap_bar();
        
    for(x = [-1, 1]) translate([x * (box_width/2 - wall_thickness - clearance/2), 0, z_pos]) 
        rotate([0, 0, (x > 0) ? 90 : -90]) chamfered_snap_bar();
}

if (part == "wall") {
    wall_mount();
} else if (part == "cover") {
    rotate([180, 0, 0]) translate([0, 0, -box_depth]) front_cover();
} else {
    color("MediumSeaGreen") wall_mount();
    translate([0, 0, 15]) color("SkyBlue", 0.4) front_cover();
}