Added vero_bed config option for huxley.

Moved screw sizes to vitamins.scad so it can be used stand alone.
Added capped option to hole_support.
Fixed bug in rounded_cylinder().

dibond/stls/printed/wades_extruder.stl

@@ -3761,10 +3761,17 @@ solid OpenSCAD_Model
   facet normal 1.15659e-005 -1 2.563e-006
     outer loop
       vertex 106.939 9.53672e-007 14.8407
-      vertex 107.06 1.4732e-012 13.9238
+      vertex 107.06 0 13.9238
       vertex 106.939 9.53674e-007 14.8407
     endloop
   endfacet
+  facet normal 3.98948e-006 1 -5.14922e-007
+    outer loop
+      vertex 106.939 9.53672e-007 14.8407
+      vertex 107.06 1.4732e-012 13.9238
+      vertex 107.06 0 13.9238
+    endloop
+  endfacet
   facet normal 0.991443 0 -0.130537
     outer loop
       vertex 106.939 9.53674e-007 11.1593
@@ -3793,13 +3800,6 @@ solid OpenSCAD_Model
       vertex 106.999 3 14.3823
     endloop
   endfacet
-  facet normal 3.9895e-006 1 -5.14922e-007
-    outer loop
-      vertex 106.939 9.53674e-007 14.8407
-      vertex 107.06 1.4732e-012 13.9238
-      vertex 107.06 0 13.9238
-    endloop
-  endfacet
   facet normal 0.991443 0 -0.130537
     outer loop
       vertex 106.999 3 11.6177

dibond/stls/wades_block.stl

@@ -1441,7 +1441,7 @@ solid OpenSCAD_Model
       vertex 106.739 3 10.2565
     endloop
   endfacet
-  facet normal 0.953721 0 0.300692
+  facet normal 0.953721 -0 0.300692
     outer loop
       vertex 106.461 9.53673e-007 16.6254
       vertex 106.739 0 15.7435
@@ -1595,7 +1595,7 @@ solid OpenSCAD_Model
       vertex 106.939 9.53672e-007 11.1593
     endloop
   endfacet
-  facet normal 1 -0 0
+  facet normal 1 0 0
     outer loop
       vertex 106.739 9.53672e-007 15.7435
       vertex 106.739 9.53674e-007 15.7435

scad/conf/config.scad

@@ -7,14 +7,12 @@
 //
 // Configuration file
 //
-
-function sqr(x) = x * x;            // shortcut
-
 bom = $bom == undef ? 0: $bom;                 // 0 no bom, 1 assemblies and stls, 2 vitamins as well
 exploded = $exploded == undef ? 0 : $exploded; // 1 for exploded view
 
 show_jigs = true;               // show printed jigs required to build the machine
 show_support = true;            // show support structures, must be set when generating STLs
+show_rays = false;              // show light and camera rays to check orientation is correct
 
 // Real-world colors for various parts & vitamins
 use_realistic_colors = false;    // true for "real" colors, false for "distinct" colors (useful during design and for build instructions)
@@ -27,49 +25,7 @@ eta = 0.01;                     // small fudge factor to stop CSG barfing on coi
 $fa = 5;
 $fs = 0.5;
 
-//
+function sqr(x) = x * x;            // shortcut
-// Hole sizes
-//
-No2_pilot_radius = 1.7 / 2;       // self tapper into ABS
-No4_pilot_radius = 2.0 / 2;       // wood screw into soft wood
-No6_pilot_radius = 2.0 / 2;       // wood screw into soft wood
-
-No2_clearance_radius = 2.5 / 2;
-No4_clearance_radius = 3.5 / 2;
-No6_clearance_radius = 4.0 / 2;
-
-M2_tap_radius = 1.6 / 2;
-M2_clearance_radius = 2.4 / 2;
-M2_nut_trap_depth = 2.5;
-
-M2p5_tap_radius = 2.05 / 2;
-M2p5_clearance_radius= 2.8 / 2;   // M2.5
-M2p5_nut_trap_depth = 2.5;
-
-M3_tap_radius = 2.5 / 2;
-M3_clearance_radius = 3.3 / 2;
-M3_nut_radius = 6.5 / 2;
-M3_nut_trap_depth = 3;
-
-M4_tap_radius = 3.3 / 2;
-M4_clearance_radius = 2.2;
-M4_nut_radius = 8.2 / 2;
-M4_nut_trap_depth = 4;
-
-M5_tap_radius = 4.2 / 2;
-M5_clearance_radius = 5.3 / 2;
-M5_nut_radius = 9.2 / 2;
-M5_nut_depth = 4;
-
-M6_tap_radius = 5 / 2;
-M6_clearance_radius = 6.4 / 2;
-M6_nut_radius = 11.6 / 2;
-M6_nut_depth = 5;
-
-M8_tap_radius = 6.75 / 2;
-M8_clearance_radius = 8.4 / 2;
-M8_nut_radius = 15.4 / 2;
-M8_nut_depth = 6.5;
 
 cnc_tool_dia = 2.4;
 layer_height = 0.4;
@@ -83,7 +39,6 @@ feed_tube_tape_rad = 6.2 / 2;
 feed_tube_tape = 12;
 nozzle_length = 54;                 // how far nozzle is below top of carriage
 
-
 include <colors.scad>
 include <utils.scad>
 include <vitamins.scad>
@@ -112,6 +67,7 @@ extruder = Wades;                   // Default extruder
 raspberry_pi = false;               // Raspberry pi mounted on PSU
 raspberry_pi_camera = false;        // RPI camera on bar across the back
 light_strip = false;
+vero_bed = false;                   // Bed made from vero board rather than custom PCB.
 include <machine.scad>              // this file is generated from the command line parameter to include one of the machine configs
 
 screw_clearance_radius = screw_clearance_radius(cap_screw);
@@ -130,6 +86,7 @@ limit_switch_offset = 1;                // the over travel to reach the limit sw
 X_carriage_clearance = 2;               // how close the X carriage is to the XZ plane
                                         // how close the Y carriage is to the window in the XZ plane
 Y_carriage_clearance = 2 + (clip_handles ? (bulldog_handle_length(small_bulldog) - (Y_carriage_width - bed_width) / 2) : 0);
+Y_carriage_rad = 3;                     // corner radius
 Z_clearance = 10;                       // How close the top of the object gets to the gantry
 belt_clearance = 0.2;                   // clearance of belt clamp slots
 

scad/conf/utils.scad

@@ -13,24 +13,32 @@ include <../utils/teardrops.scad>
 include <../utils/cables.scad>
 include <../utils/shields.scad>
 
+function round_to_layer(z) = ceil(z / layer_height) * layer_height;
+
 module slot(h, r, l, center = true)
     linear_extrude(height = h, convexity = 6, center = center)
         hull() {
             translate([l/2,0,0])
-                circle(r = r, center = true);
+                circle(r);
             translate([-l/2,0,0])
-                circle(r = r, center = true);
+                circle(r);
         }
 
-module hole_support(r, h, max_r = 999, closed = false) {
+module hole_support(r, h, max_r = 999, closed = false, capped = false) {
     n = sides(r);
     cr = corrected_radius(r, n);
     ir = min(cr, max_r - 2.25 * filament_width);
     or = ir + 2 * filament_width;
     difference() {
         cylinder(r = or, h = h, $fn = n);
-        translate([0, 0, closed ? layer_height : -1])
+        difference() {
-            cylinder(r = ir, h = h + 2, $fn = n);
+            translate([0, 0, closed ? layer_height : -1])
+                cylinder(r = ir, h = h + 2, $fn = n);
+
+            if(capped)
+                translate([0, 0, h - 4 * layer_height])
+                    cylinder(r = or, h = 3 * layer_height + eta);
+        }
     }
 }
 
@@ -105,7 +113,7 @@ module rounded_square(w, h, r)
         for(x = [-w/2 + r, w/2 - r])
             for(y = [-h/2 + r, h/2 - r])
                 translate([x, y])
-                    circle(r = r);
+                    circle(r);
     }
 }
 
@@ -123,11 +131,14 @@ module rounded_rectangle(size, r, center = true)
 module rounded_cylinder(r, h, r2)
 {
     rotate_extrude()
-        union() {
+        hull() {
-            square([r - r2, h]);
+            square([1, h]);
-            square([r, h - r2]);
+            square([r, 1]);
             translate([r - r2, h - r2])
-                circle(r = r2);
+                intersection() {
+                    circle(r2);
+                    square(r2);
+                }
         }
 }
 
@@ -157,7 +168,7 @@ module tube(or, ir, h, center = true) {
 module explode(v, offset = [0,0,0]) {
     if(exploded) {
         translate(v * exploded)
-            child();
+            children();
         render() hull() {
             sphere(0.2);
             translate(v * exploded + offset)
@@ -165,16 +176,5 @@ module explode(v, offset = [0,0,0]) {
         }
     }
     else
-        child();
+        children();
 }
-//
-// Restore the view point
-//
-module view(t,r,d = 1000)
-    rotate([55, 0, 25])
-        translate([0, 0, -d + 500])
-            rotate([-r[0], 0, 0])
-                rotate([0, -r[1], 0])
-                    rotate([0, 0, -r[2]])
-                        translate(-t)
-                            child();

scad/conf/vitamins.scad

@@ -7,6 +7,50 @@
 //
 // Off the shelf parts
 //
+//
+// Hole sizes
+//
+No2_pilot_radius = 1.7 / 2;       // self tapper into ABS
+No4_pilot_radius = 2.0 / 2;       // wood screw into soft wood
+No6_pilot_radius = 2.0 / 2;       // wood screw into soft wood
+
+No2_clearance_radius = 2.5 / 2;
+No4_clearance_radius = 3.5 / 2;
+No6_clearance_radius = 4.0 / 2;
+
+M2_tap_radius = 1.6 / 2;
+M2_clearance_radius = 2.4 / 2;
+M2_nut_trap_depth = 2.5;
+
+M2p5_tap_radius = 2.05 / 2;
+M2p5_clearance_radius= 2.8 / 2;   // M2.5
+M2p5_nut_trap_depth = 2.5;
+
+M3_tap_radius = 2.5 / 2;
+M3_clearance_radius = 3.3 / 2;
+M3_nut_radius = 6.5 / 2;
+M3_nut_trap_depth = 3;
+
+M4_tap_radius = 3.3 / 2;
+M4_clearance_radius = 2.2;
+M4_nut_radius = 8.2 / 2;
+M4_nut_trap_depth = 4;
+
+M5_tap_radius = 4.2 / 2;
+M5_clearance_radius = 5.3 / 2;
+M5_nut_radius = 9.2 / 2;
+M5_nut_depth = 4;
+
+M6_tap_radius = 5 / 2;
+M6_clearance_radius = 6.4 / 2;
+M6_nut_radius = 11.6 / 2;
+M6_nut_depth = 5;
+
+M8_tap_radius = 6.75 / 2;
+M8_clearance_radius = 8.4 / 2;
+M8_nut_radius = 15.4 / 2;
+M8_nut_depth = 6.5;
+
 include <../vitamins/washers.scad>
 include <../vitamins/nuts.scad>
 include <../vitamins/screws.scad>

stls.py

@@ -100,4 +100,4 @@ if __name__ == '__main__':
         stls(sys.argv[1], sys.argv[2:])
     else:
         print("usage: stls dibond|mendel|sturdy|your_machine [part.stl ...]")
-    sys.exit(1)
+        sys.exit(1)