Added rounded corners to some parts to make them easier to print.

Filled some gaps in the X ends to make them faster to print.
D motor bracket lid now one piece again, as PCB now clears it.
Calibration object now includes horizontal nut traps.
Add c14n_stl.py to canonicalise the STL files.
Corrected PLA sample diameter.
Removed feed tube connector, works fine without it.
Removed tube jig as not required in the kit.
Manual updated with new part renders.

c14n_stl.py

@@ -0,0 +1,83 @@
+#!/usr/bin/env python
+#
+# OpenSCAD produces randomly ordered STL files so source control like GIT can't tell if they have changed or not.
+# This scrip orders each triangle to start with the lowest vertex first (comparing x, then y, then z)
+# It then sorts the triangles to start with the one with the lowest vertices first (comparing first vertex, second, then third)
+# This has no effect on the model but makes the STL consistent. I.e. it makes a canonical form.
+#
+import sys
+
+class Vertex:
+    def __init__(self, x, y, z):
+        self.x, self.y, self.z = x, y, z
+        self.key = (float(x), float(y), float(z))
+
+class Normal:
+    def __init__(self, dx, dy, dz):
+        self.dx, self.dy, self.dz = dx, dy, dz
+
+class Facet:
+    def __init__(self, normal, v1, v2, v3):
+        self.normal = normal
+        if v1.key < v2.key:
+            if v1.key < v3.key:
+                self.vertices = (v1, v2, v3)    #v1 is the smallest
+            else:
+                self.vertices = (v3, v1, v2)    #v3 is the smallest
+        else:
+            if v2.key < v3.key:
+                self.vertices = (v2, v3, v1)    #v2 is the smallest
+            else:
+                self.vertices = (v3, v1, v2)    #v3 is the smallest
+
+    def key(self):
+        return (self.vertices[0].x, self.vertices[0].y, self.vertices[0].z,
+                self.vertices[1].x, self.vertices[1].y, self.vertices[1].z,
+                self.vertices[2].x, self.vertices[2].y, self.vertices[2].z)
+
+class STL:
+    def __init__(self, fname):
+        self.facets = []
+
+        f = open(fname)
+        words = [s.strip() for s in f.read().split()]
+        f.close()
+
+        if words[0] == 'solid' and words[1] == 'OpenSCAD_Model':
+            i = 2
+            while words[i] == 'facet':
+                norm = Normal(words[i + 2],  words[i + 3],  words[i + 4])
+                v1   = Vertex(words[i + 8],  words[i + 9],  words[i + 10])
+                v2   = Vertex(words[i + 12], words[i + 13], words[i + 14])
+                v3   = Vertex(words[i + 16], words[i + 17], words[i + 18])
+                i += 21
+                self.facets.append(Facet(norm, v1, v2, v3))
+
+            self.facets.sort(key = Facet.key)
+        else:
+            print "Not an OpenSCAD ascii STL file"
+            sys.exit(1)
+
+    def write(self, fname):
+        f = open(fname,"wt")
+        print >> f,'solid OpenSCAD_Model'
+        for facet in self.facets:
+            print >> f, '  facet normal %s %s %s' % (facet.normal.dx, facet.normal.dy, facet.normal.dz)
+            print >> f, '    outer loop'
+            for vertex in facet.vertices:
+                print >> f, '      vertex %s %s %s' % (vertex.x, vertex.y, vertex.z)
+            print  >> f, '    endloop'
+            print  >> f, '  endfacet'
+        print >> f, 'endsolid OpenSCAD_Model'
+        f.close()
+
+def canonicalise(fname):
+    stl = STL(fname)
+    stl.write(fname)
+
+if __name__ == '__main__':
+    if len(sys.argv) == 2:
+        canonicalise(sys.argv[1])
+    else:
+        print "usage: c14n_stl file"
+        sys.exit(1)

dibond/bom/bom.txt

@@ -76,7 +76,7 @@ Vitamins:
   |  |  |  |  |  |  |  |  |  | 4|  |  |  |  |  |  |  |  |  |  |  |  4 Nyloc nut M8
   |  |  |  |  |  |  |  |  |  |  |  |  |  |  | 2|  |  |  |  |  |  |  2 Nitrile O-ring 2.5mm x 1.6mm
   |  |  | 1|  |  |  |  |  |  |  |  |  |  |  |  |  |  |  |  |  |  |  1 Extruder connection PCB
-  |  |  |  |  |  |  |  |  |  | 1|  |  |  |  |  |  |  |  |  |  |  |  1 PLA sample 0.3mm ~20m
+  |  |  |  |  |  |  |  |  |  | 1|  |  |  |  |  |  |  |  |  |  |  |  1 PLA sample 3mm ~20m
   |  |  |  |  |  |  |  |  |  |  |  |  |  |  | 1|  |  |  |  |  |  |  1 Polypropylene strip 401mm x 18mm x 0.5mm
   |  |  |  |  |  |  |  |  |  |  |  |  |  |  | 1|  |  |  |  |  |  |  1 Polypropylene strip 457mm x 25mm x 0.5mm
   |  |  |  |  |  |  |  | 1|  |  |  |  |  |  |  |  |  |  |  |  |  |  1 Polypropylene strip 271mm x 33mm x 0.5mm
@@ -136,7 +136,6 @@ Printed:
   |  |  |  |  |  |  |  |  |  |  |  |  |  |  | 1|  |  |  |  |  |  |  1 d_shell_lid.stl
   |  |  |  |  |  |  |  |  |  | 1|  |  |  |  |  |  |  |  |  |  |  |  1 dust_filter.stl
  1|  |  |  |  |  |  |  |  |  |  |  |  |  |  |  |  |  |  |  |  |  |  1 fan_guard.stl
-  |  |  |  |  |  |  |  |  |  | 1|  |  |  |  |  |  |  |  |  |  |  |  1 feed_tube_connector.stl
   |  |  |  |  |10|  |  |  |  |  |  |  |  |  |  |  |  |  |  |  |  | 10 fixing_block.stl
   | 4|  |  |  |  |  |  |  |  |  |  |  |  |  |  |  |  |  |  |  |  |  4 pcb_spacer.stl
   |  |  |  |  |  |  |  |  |  |  |  |  |  |  | 1|  |  |  |  |  |  |  1 ribbon_clamp_14_33.stl
@@ -149,7 +148,6 @@ Printed:
   |  |  |  |  |  |  |  |  |  | 2|  |  |  |  |  |  |  |  |  |  |  |  2 spool_bracket_female.stl
   |  |  |  |  |  |  |  |  |  | 2|  |  |  |  |  |  |  |  |  |  |  |  2 spool_bracket_male.stl
   |  |  |  |  | 4|  |  |  |  |  |  |  |  |  |  |  |  |  |  |  |  |  4 tube_cap.stl
-  |  |  |  |  | 1|  |  |  |  |  |  |  |  |  |  |  |  |  |  |  |  |  1 tube_jig.stl
   |  | 1|  |  |  |  |  |  |  |  |  |  |  |  |  |  |  |  |  |  |  |  1 wades_big_gear.stl
   |  | 1|  |  |  |  |  |  |  |  |  |  |  |  |  |  |  |  |  |  |  |  1 wades_block.stl
   |  | 1|  |  |  |  |  |  |  |  |  |  |  |  |  |  |  |  |  |  |  |  1 wades_gear_spacer.stl

dibond/bom/frame_assembly.txt

@@ -14,5 +14,4 @@ Printed:
   1 ribbon_clamp_20_44N.stl
   1 ribbon_clamp_26_44N.stl
   4 tube_cap.stl
-  1 tube_jig.stl
 

dibond/bom/spool_holder_assembly.txt

@@ -6,7 +6,7 @@ Vitamins:
   1 Foam sponge 20mm x 20mm x 20mm
   2 Nyloc nut M4
   4 Nyloc nut M8
-  1 PLA sample 0.3mm ~20m
+  1 PLA sample 3mm ~20m
   1 PTFE tubing OD 4.6mm ID 3.84mm x 750mm
   2 Washer M4 x 9mm x 0.8mm
   8 Washer M8 x 17mm x 1.6mm
@@ -14,7 +14,6 @@ Vitamins:
 
 Printed:
   1 dust_filter.stl
-  1 feed_tube_connector.stl
   2 spool_bracket_female.stl
   2 spool_bracket_male.stl