// Round badge: text set around a circle, letter by letter. Each letter is
// measured, then placed and turned to follow the ring, so any words fit.
// A start for logos, coasters, seals and patches.

/* [Text] */
// Around the top
top_text = "HANDMADE WITH CARE"; // 32
// Around the bottom
bottom_text = "EST. 2026"; // 24
// In the middle
centre_text = "KS"; // 4

/* [Badge] */
// Diameter
size = 90; // [50:5:200]
// Edge of the badge
edge = "scalloped"; // [round:Round, scalloped:Scalloped]
// Engraved text on plain wood, or plain text on an engraved ring
style = "text"; // [text:Engraved text, band:Engraved ring]
// A hole to hang it from
hole = false;

/* [Material] */
// Sheet thickness
$thickness = 3; // [2:0.5:6]
// Beam width
$kerf = 0.15; // [0:0.01:0.3]

/* [Hidden] */
$material = "plywood";
$fn = 120;
r = size / 2;
band_out = r * 0.86;
band_in = r * 0.62;
letters = (band_out - band_in) * 0.5;
mid = (band_out + band_in) / 2;

// Width of the first i letters of s
function before(s, i) = i == 0 ? 0 : text_width(slice(s, 0, i), letters);

// Angle, in degrees, of the middle of letter i on a circle of radius rr
function angle_of(s, i, rr) = (before(s, i) + text_width(s[i], letters) / 2) * 180 / (PI * rr);

// Top text runs clockwise with the letters standing on the ring
module top_arc(s) {
  rr = mid - letters * 0.36;
  span = text_width(s, letters) * 180 / (PI * rr);
  for (i = [0:len(s) - 1]) rotate(90 + span / 2 - angle_of(s, i, rr))
    translate([rr, 0]) rotate(-90) text(s[i], size = letters, halign = "center");
}

// Bottom text runs anticlockwise, so it reads left to right the right way up
module bottom_arc(s) {
  rr = mid + letters * 0.36;
  span = text_width(s, letters) * 180 / (PI * rr);
  for (i = [0:len(s) - 1]) rotate(270 - span / 2 + angle_of(s, i, rr))
    translate([rr, 0]) rotate(90) text(s[i], size = letters, halign = "center");
}

module words() {
  if (top_text != "") top_arc(top_text);
  if (bottom_text != "") bottom_arc(bottom_text);
  // Stars between the two lines of text
  for (x = [-1, 1]) translate([x * mid, 0]) star(5, letters * 0.4, letters * 0.17);
}

module outline_shape() {
  if (edge == "round") circle(r = r);
  else union() {
    circle(r = r * 0.95);
    for (a = [0:10:350]) rotate(a) translate([r * 0.95, 0]) circle(r = r * 0.05, $fn = 24);
  }
}

difference() {
  union() {
    outline_shape();
    if (hole) translate([0, r]) circle(d = 12);
  }
  if (hole) translate([0, r + 1]) circle(d = 5);
}

engrave() {
  if (style == "band") difference() {
    circle(r = band_out);
    circle(r = band_in);
    words();
  }
  else words();
  if (centre_text != "") text(centre_text, size = band_in * 0.62, halign = "center", valign = "center");
}

// outline() keeps each circle a line of its own; filled circles would merge
score() for (rr = [band_out + 1.2, band_in - 1.2, band_in - 3]) outline() circle(r = rr);