Parametric model of a USB-C style connector shell, rear housing, and swept cable.

// USB-C Connector Assembly
// Parametric model of a USB-C style connector shell, rear housing, and swept cable.
// Categories: Electronics, Connector, Consumer Hardware

@settings(defaultLengthUnit = mm)

// Outer shell dimensions and wall settings
shellLength = 6.8
shellWidth = 8.4
shellHeight = 2.6
shellCornerRadius = 1.1
shellWall = 0.3
rearWall = 0.9
frontCutOvertravel = 0.2

// Inner cavity dimensions derived from shell parameters
innerWidth = shellWidth - (shellWall * 2)
innerHeight = shellHeight - (shellWall * 2)
innerCornerRadius = 0.55
cavityLength = shellLength - rearWall + frontCutOvertravel

// Contact tongue dimensions and front offset
tongueLength = 5.4
tongueWidth = 6.6
tongueHeight = 0.8
tongueInsetFromFront = 0.35
tongueStartX = shellLength - tongueLength - tongueInsetFromFront

// Rear housing dimensions
housingLength = 14
housingWidth = 12
housingHeight = 4.6
housingCornerRadius = 1.6

// Cable geometry parameters (radius and path)
cableRadius = 1.9
cableLeadLength = 12
cableBendRadius = 22
cableTailLength = 52

// Sketch the outer shell cross-section on YZ
shellProfile = startSketchOn(YZ)
  |> startProfile(at = [-shellWidth / 2, -shellHeight / 2])
  |> xLine(length = shellWidth, tag = $shellEdge01)
  |> yLine(length = shellHeight, tag = $shellEdge02)
  |> xLine(length = -shellWidth, tag = $shellEdge03)
  |> close(tag = $shellEdge04)

// Extrude and fillet the shell body
shellBody = extrude(shellProfile, length = shellLength)
  |> fillet(
       radius = shellCornerRadius,
       tags = [
         getNextAdjacentEdge(shellEdge01),
         getNextAdjacentEdge(shellEdge02),
         getNextAdjacentEdge(shellEdge03),
         getNextAdjacentEdge(shellEdge04)
       ],
     )

// Sketch the inner cavity profile on an offset plane
cavityProfile = startSketchOn(offsetPlane(YZ, offset = rearWall))
  |> startProfile(at = [-innerWidth / 2, -innerHeight / 2])
  |> xLine(length = innerWidth, tag = $cavityEdge01)
  |> yLine(length = innerHeight, tag = $cavityEdge02)
  |> xLine(length = -innerWidth, tag = $cavityEdge03)
  |> close(tag = $cavityEdge04)

// Extrude and fillet the cavity cutter
cavityBody = extrude(cavityProfile, length = cavityLength)
  |> fillet(
       radius = innerCornerRadius,
       tags = [
         getNextAdjacentEdge(cavityEdge01),
         getNextAdjacentEdge(cavityEdge02),
         getNextAdjacentEdge(cavityEdge03),
         getNextAdjacentEdge(cavityEdge04)
       ],
     )

// Subtract cavity from shell and set shell appearance
shell = subtract(shellBody, tools = cavityBody)
  |> appearance(color = "#d0d5de", metalness = 88, roughness = 20)

// Create the internal tongue block
tongue = startSketchOn(offsetPlane(YZ, offset = tongueStartX))
  |> rectangle(center = [0, 0], width = tongueWidth, height = tongueHeight)
  |> extrude(length = tongueLength)
  |> appearance(color = "#f2f2f2", metalness = 0, roughness = 70)

// Sketch the rear housing cross-section on YZ
housingProfile = startSketchOn(YZ)
  |> startProfile(at = [-housingWidth / 2, -housingHeight / 2])
  |> xLine(length = housingWidth, tag = $housingEdge01)
  |> yLine(length = housingHeight, tag = $housingEdge02)
  |> xLine(length = -housingWidth, tag = $housingEdge03)
  |> close(tag = $housingEdge04)

// Extrude and fillet rear housing, then set appearance
housing = extrude(housingProfile, length = -housingLength)
  |> fillet(
       radius = housingCornerRadius,
       tags = [
         getNextAdjacentEdge(housingEdge01),
         getNextAdjacentEdge(housingEdge02),
         getNextAdjacentEdge(housingEdge03),
         getNextAdjacentEdge(housingEdge04)
       ],
     )
  |> appearance(color = "#1b1b1b", metalness = 4, roughness = 72)

// Sketch the cable centerline path on XZ
cablePath = startSketchOn(XZ)
  |> startProfile(at = [-housingLength, 0])
  |> line(end = [-cableLeadLength, 0])
  |> tangentialArc(radius = cableBendRadius, angle = -55deg, tag = $cableBend)
  |> angledLine(angle = tangentToEnd(cableBend), length = cableTailLength)

// Sweep cable profile along the path and set appearance
cable = startSketchOn(offsetPlane(YZ, offset = -housingLength))
  |> circle(center = [0, 0], radius = cableRadius)
  |> sweep(path = cablePath)
  |> appearance(color = "#101010", metalness = 0, roughness = 80)


USB-C Connector Assembly

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