Mods to carriage for Huxley.

Fan duct bracket screws longer for easier removal and replacement.
Direct 1.75mm drive extruder for Huxley.
MK5B J-head model length corrected to match reality.

dibond/bom/bom.txt

@@ -32,8 +32,8 @@ Vitamins:
   |  |  |  |  |  |  |  |  |  |  |  |  |  |  |  | 1|  |  |  |  |  |  1 Belt T2 x 6mm x 662mm
   |  |  |  |  |  |  |  |  |  |  | 1|  |  |  |  |  |  |  |  |  |  |  1 Belt T2 x 6mm x 860mm
   |  |  |  |  |  |  |  | 4|  |  |  |  |  |  |  |  |  |  |  |  |  |  4 Corrugated cardboard 201mm x 216mm x 5mm
-  |  |  |  |  |  |  |  | 4|  |  |  | 2|  |  |  |  |  |  |  |  |  |  6 M3 cap screw x 10mm
-  | 4| 3|  |  |  |  |  |  |  |  |  |  |  |  | 6| 4|14|  |  | 2| 2| 35 M3 cap screw x 16mm
+  |  |  |  |  |  |  |  | 4|  |  |  |  |  |  |  |  |  |  |  |  |  |  4 M3 cap screw x 10mm
+  | 4| 3|  |  |  |  |  |  |  |  |  | 2|  |  | 6| 4|14|  |  | 2| 2| 37 M3 cap screw x 16mm
   |  |  |  |  |  |  |  |  |  |  |  | 1|  | 8|10|  | 2|  |  |  | 8| 29 M3 cap screw x 20mm
   |  |  |  |  |  |  |  |  |  |  |  | 2|  |  |  |  |  |  |  |  |  |  2 M3 cap screw x 25mm
   |  |  |  | 2|  |  |  |  |  |  |  |  |  |  | 2|  |  |  |  |  |  |  4 M3 cap screw x 45mm

dibond/bom/x_carriage_assembly.txt

@@ -1,6 +1,6 @@
 x_carriage_assembly:
 Vitamins:
-  2 M3 cap screw x 10mm
+  2 M3 cap screw x 16mm
   1 M3 cap screw x 20mm
   2 M3 cap screw x 25mm
   3 LM8UU linear bearing

scad/conf/config.scad

@@ -75,6 +75,7 @@ thermistor_wires_hole_radius = wire_hole_radius(thermistor_wires);
 
 cnc_sheets = false;                 // If sheets are cut by CNC we can use slots, etc instead of just round holes
 base_nuts = false;                  // Need something under the base if using nuts
+pulley_type = T5x8_plastic_pulley;
 clip_handles = true;
 include_fan = false;
 squeeze = false;                    // Bodge to make Huxley as small as possible without affecting dibond kits
@@ -106,9 +107,9 @@ 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
 
-X_bar_dia = X_bearings[2];      // rod sizes to match the bearings
-Y_bar_dia = Y_bearings[2];
-Z_bar_dia = Z_bearings[2];
+X_bar_dia = bearing_rod_dia(X_bearings);      // rod sizes to match the bearings
+Y_bar_dia = bearing_rod_dia(Y_bearings);
+Z_bar_dia = bearing_rod_dia(Z_bearings);
 
 Y_idler_bearing = BB624;
 X_idler_bearing = BB624;

scad/conf/huxley_config.scad

@@ -17,32 +17,41 @@ X_motor = NEMA14;
 Y_motor = NEMA14;
 Z_motor = NEMA14;
 
-hot_end = JHeadMk5;
+hot_end = JHeadMk5x;
+extruder = Direct14;
 
-X_travel = 150;
+X_travel = 152;
 Y_travel = 150;
 Z_travel = 150;
 
-bed_depth = 164;
-bed_width = 114;
+vero_bed = true;
+x_holes = round(150 / 2.54) + 6;
+y_holes = round(Y_travel / 2.54) + 4;
+
+bed_depth = 160;        // 59 + 4 holes
+bed_width = 165;        // 59 + 6 holes
 bed_pillars = M3x20_pillar;
 bed_glass = glass2;
 bed_thickness = pcb_thickness + sheet_thickness(bed_glass);    // PCB heater plus glass sheet
-bed_holes = [bed_width - 2 * 2.54, bed_depth - 2 * 2.54];
+bed_holes = [(x_holes - 3) * 2.54, (y_holes - 3) * 2.54];
 
 base = DiBond;                  // Sheet material used for the base. Needs to be thick enough to screw into.
 base_corners = 25;
 base_nuts = true;
+squeeze = true;
 
 frame = DiBond;
 frame_corners = 25;
 frame_nuts = true;
 
-case_fan = fan80x38;
+case_fan = fan80x25;
 part_fan = fan40x11;
 
 psu = External;
 controller = Melzi;
+raspberry_pi = true;
+raspberry_pi_camera = true;
+light_strip =  RIGID5050_208;
 
 spool = spool_200x55;
 bottom_limit_switch = false;
@@ -53,23 +62,21 @@ clip_handles = false;
 single_piece_frame = true;
 stays_from_window = false;
 cnc_sheets = true;                 // If sheets are cut by CNC we can use slots, etc instead of just round holes
-pulley_type = T2p5x16_metal_pulley;
+pulley_type = GT2x20_metal_pulley;
 
 Y_carriage = DiBond;
 
-pulley_type = GT2x20_metal_pulley;
 X_belt = GT2x6;
 Y_belt = GT2x6;
-
 motor_shaft = 5;
 Z_screw_dia = 5;            // Studding for Z axis
 
 Y_carriage_depth = bed_holes[1] + 7;
-Y_carriage_width = bed_holes[1] + 7;
+Y_carriage_width = bed_holes[0] + 7;
 
-Z_nut_radius = M6_nut_radius;
-Z_nut_depth = M6_nut_depth;
-Z_nut = M6_nut;
+Z_nut_radius = M5_nut_radius;
+Z_nut_depth = M5_nut_depth;
+Z_nut = M5_nut;
 
 //
 // Default screw use where size doesn't matter
@@ -85,5 +92,5 @@ frame_thick_screw = M3_pan_screw;           // Used with tapped holes when sheet
 //
 // Feature sizes
 //
-default_wall = 3;
+default_wall = 2;
 thick_wall = 3;

scad/direct.scad

@@ -0,0 +1,512 @@
+//
+// Mendel90
+//
+// GNU GPL v2
+// nop.head@gmail.com
+// hydraraptor.blogspot.com
+//
+// Direct drive extruder
+//
+include <conf/config.scad>
+use <d-motor_bracket.scad>
+use <vitamins/jhead_hot_end.scad>
+
+MiniHyena = [5, 8, 13, 4, 6.3, 5.3, 1.5, 9, M3_grub_screw, 3];
+
+function hobbed_id(type)         = type[0];
+function hobbed_od(type)         = type[1];
+function hobbed_length(type)     = type[2];
+function hobbed_offset(type)     = type[3];
+function hobbed_hob_od(type)     = type[4];
+function hobbed_hob_id(type)     = type[5];
+function hobbed_hob_radius(type) = type[6];
+function hobbed_screw_z(type)    = type[7];
+function hobbed_screw_type(type) = type[8];
+function hobbed_screw_l(type)    = type[9];
+
+
+module hobbed_pulley(type) {
+    od = hobbed_od(type);
+    id = hobbed_id(type);
+    len = hobbed_length(type);
+    vitamin(str("HOB",od, id, len, ": hobbed pulley ", od, ,"x", id));
+
+    color("DarkGoldenrod") render() difference() {
+        cylinder(r = od / 2, h = len);
+        cylinder(r = id / 2, h = len * 2 + 1, center = true);
+        translate([0, 0, hobbed_offset(type)])
+            rotate_extrude(a = 360)
+                translate([hobbed_hob_od(type) / 2 + hobbed_hob_radius(type), 0])
+                    circle(r = hobbed_hob_radius(type));
+
+        translate([0, 0, hobbed_screw_z(type)])
+            rotate([-90, 0, 0])
+                cylinder(r = screw_radius(hobbed_screw_type(type)), h = od / 2 + 1);
+    }
+}
+
+module hobbed_pulley_assembly(type) {
+    hobbed_pulley(type);
+    translate([0, hobbed_id(type) / 2 + hobbed_screw_l(type) - 0.5, hobbed_screw_z(type)])
+        rotate([-90, 0, 0])
+            screw(hobbed_screw_type(type), hobbed_screw_l(type));
+}
+
+peg_spring = [ 6.5,    0.96, 16, 8];
+
+pulley = MiniHyena;
+idler = BB624;
+motor = extruder_motor(extruder);
+spring = peg_spring;
+
+compressed_spring = 9.5;
+
+width = extruder_width(extruder);
+length = extruder_length(extruder);
+motor_thickness = 5;
+base_thickness = 8;
+height = base_thickness + NEMA_width(motor) + 1;
+
+filament_r = 1.75 / 2;
+filament_x = 0;
+filament_z = width / 2;
+filament_path_r = 1;
+
+motor_y = height - NEMA_width(motor) / 2 - 1;
+motor_x = filament_x + filament_r + hobbed_hob_id(pulley) / 2;
+motor_z = 0;
+
+motor_plate_width = NEMA_width(motor) + 2;
+motor_plate_rad = (motor_plate_width - NEMA_hole_pitch(motor)) / 2;
+mount_pitch = 25;
+
+idler_closed_x = motor_x - hobbed_od(pulley) / 2 - ball_bearing_diameter(idler) / 2;
+idler_x = filament_x - filament_r - ball_bearing_diameter(idler) / 2;
+idler_z = filament_z;
+idler_y = motor_y;
+idler_clearance = 1;
+
+motor_screw_offset = NEMA_hole_pitch(motor) / 2;
+
+idler_pivot_x = motor_x - motor_screw_offset;
+idler_pivot_y = motor_y + motor_screw_offset;
+
+idler_swing_r = sqrt(sqr(idler_x -idler_pivot_x) + sqr(idler_y - idler_pivot_y));
+idler_max_swing = atan((idler_closed_x - idler_pivot_x) / idler_swing_r);
+
+lever_bottom_y = base_thickness + 1;
+lever_width = 2 * motor_plate_rad + 1;
+
+spring_x = idler_pivot_x - lever_width / 2;
+spring_z = filament_z + filament_path_r + 3 * layer_height + screw_clearance_radius(M3_cap_screw);
+spring_y = lever_bottom_y + 5;
+
+jhead_screw = M3_cap_screw;
+jhead_screw_length = 16;
+jhead_washer = M4_washer;
+jhead_screw_pitch = max(hot_end_insulator_diameter(hot_end) / 2 + screw_head_radius(jhead_screw),
+                          jhead_groove_dia() / 2 + washer_diameter(jhead_washer) / 2);
+
+angle = 30;
+
+jhead_screw_angles = [angle, -angle, 180 - angle, -180 + angle];
+
+jhead_nut_slot = nut_thickness(screw_nut(jhead_screw)) + 0.3;
+
+extension = max(0, nozzle_length - hot_end_length(hot_end));
+extension_width = extruder_hole(extruder)[0] - 1;
+extension_rad = jhead_screw_pitch + 5;
+extension_clearance = 1;
+
+jhead_nut_pos = -extension - base_thickness + 2 + jhead_nut_slot;
+
+filament_top_guide_r = tubing_od(PF7) / 2 + 2;
+
+function direct_extruder_connector_offset() = [-motor_x, -width / 2, motor_y] + d_motor_connector_offset();
+
+idler_clearance_r = ball_bearing_diameter(idler) / 2 + idler_closed_x - idler_x;
+
+
+filament_bottom_guide_w = 2 * (filament_path_r + layer_height / 4 + min_wall);
+filament_lower_gap = sqrt(sqr(idler_clearance_r) - sqr(idler_x - filament_x + filament_bottom_guide_w / 2));
+filament_bottom_guide_length = idler_y - filament_lower_gap;
+filament_botton_guide_height = filament_z - hobbed_offset(pulley) + hobbed_screw_z(pulley) - screw_radius(hobbed_screw_type(pulley)) - 0.5;
+filament_bottom_guide_x = filament_x - filament_bottom_guide_w / 2;
+bulkhead_x = filament_bottom_guide_x;
+bulkhead_depth = filament_x + cos(angle) * jhead_screw_pitch - nut_trap_flat_radius(screw_nut(jhead_screw)) - bulkhead_x;
+
+grub_screw_clearance_r = NEMA_shaft_dia(motor) / 2 + hobbed_screw_l(pulley);
+
+module keyhole(r, h, l) {
+    R = r + layer_height / 4;
+    waist = 2 * R - 1;
+    entrance = 2 * R + 0.5;
+    y = sqrt(R * R - waist * waist / 4);
+    teardrop(h = h, r = R, center = true);
+}
+
+module direct_block_stl(include_support = true) {
+    stl("direct_block");
+
+    feed_tube_socket = 5;
+    insulator = hot_end_insulator_diameter(hot_end);
+    screw_pitch = hot_end_screw_pitch(hot_end);
+    insulator_depth = hot_end_inset(hot_end);
+
+    base_rad = 10.6;
+
+
+    filament_top_guide_length = feed_tube_socket + 2;
+    filament_top_guide_top = height + filament_top_guide_length - eta;
+
+    nut_channel_width = 2 * nut_radius(M4_nut) + 0.2;
+    nut_channel_z = idler_z - ball_bearing_width(idler) / 2 - nut_thickness(M4_nut) - layer_height;
+
+    difference(){
+        union(){
+            //
+            // motor plate
+            //
+            translate([motor_x - motor_plate_width / 2, 0, 0]){
+                hull() {
+                    cube([motor_plate_width, 1, motor_thickness]);
+
+                    for(x = [motor_plate_rad, motor_plate_width - motor_plate_rad])
+                        translate([x, height - motor_plate_rad, 0])
+                            cylinder(r = motor_plate_rad, h = motor_thickness);
+                }
+            }
+            //
+            // Filament guide
+            //
+            translate([bulkhead_x, 0, 0])
+                cube([bulkhead_depth, motor_y - grub_screw_clearance_r, width]);
+
+            translate([filament_bottom_guide_x, 0, 0])
+                cube([filament_bottom_guide_w, filament_bottom_guide_length, filament_botton_guide_height]);
+
+            hull() {
+                translate([filament_x, filament_top_guide_top - filament_top_guide_length, filament_z])
+                    rotate([-90, 0, 0])
+                        cylinder(r = filament_top_guide_r, h = filament_top_guide_length);
+
+                translate([filament_x - filament_top_guide_r, filament_top_guide_top - filament_top_guide_length, 0])
+                    cube([filament_top_guide_r * 2, filament_top_guide_length, 1]);
+            }
+            // base
+            hull()
+                for(end = [-1 , 1])
+                    translate([end * (length / 2 - base_rad), base_thickness / 2, filament_z])
+                        intersection() {
+                            union() {
+                                for(a = [-90, 90])
+                                    rotate([a, 0, 0])
+                                        teardrop(r = base_rad, h = base_thickness, truncate = false, center = true);
+                            }
+                            cube([width * 2, base_thickness + 1, width], center = true);
+                        }
+
+            if(extension)
+                translate([filament_x - extension_width / 2, -extension + extension_clearance + eta, 0])
+                    intersection() {
+                        cube([extension_width, extension - extension_clearance, width]);
+                        translate([extension_width / 2, extension / 2, filament_z])
+                            rotate([-90, 0, 0])
+                                teardrop(r = extension_rad, h = extension + 1, center = true);
+                    }
+        }
+
+        // filament path
+        translate([filament_x, 0, filament_z])
+            rotate([90,0,0]) {
+                teardrop_plus(h = 2 * filament_top_guide_top + 1, r = filament_path_r, center=true);   // filament
+
+                translate([0, 0, -filament_top_guide_top])
+                    teardrop_plus(h = feed_tube_socket * 2, r = tubing_od(PF7) / 2, center = true);   // feed tube
+            }
+        //
+        // idler tension screw
+        //
+        translate([bulkhead_x + bulkhead_depth, spring_y, spring_z])
+            rotate([90, 0, 90])
+                nut_trap(screw_clearance_radius(M4_cap_screw), nut_radius(M4_nut), nut_thickness(M4_nut), horizontal = true);
+        //
+        // Bearing nut channel
+        //
+        translate([idler_pivot_x, idler_pivot_y, nut_channel_z])
+            linear_extrude(height = 100)
+                hull() {
+                    translate([0, -idler_swing_r])
+                        circle(nut_channel_width / 2);
+
+                    rotate([0, 0, idler_max_swing])
+                        translate([0, -idler_swing_r])
+                            circle(nut_channel_width / 2);
+                }
+
+        // mounting holes
+        for(side = [-1, 1])
+            translate([filament_x + mount_pitch * side, base_thickness, filament_z])
+                rotate([90,0,0])
+                    intersection () {
+                        nut_trap(M4_clearance_radius, M4_nut_radius, 3, true);
+                        translate([0, 0, base_thickness / 2])
+                            cylinder(r = 20, h = base_thickness + 1, center = true);
+                    }
+        //
+        // holes for motor
+        //
+        translate([motor_x, motor_y, 0]) {
+            hub_recess = round_to_layer(NEMA_boss_height(motor)) + layer_height;
+            poly_cylinder(r = NEMA_big_hole(motor), h = hub_recess * 2, center = true);     // motor hub slot
+
+            translate([0, 0, hub_recess + (include_support ? layer_height : -1)])
+                poly_cylinder(r = hobbed_od(pulley) / 2 + 0.5, h = width, center = false);  // hole for shaft and pulley
+
+            for(x = NEMA_holes(motor))                                                      // motor screw slots
+                for(y = NEMA_holes(motor))
+                    translate([x, y, -1])
+                        poly_cylinder(r = M3_clearance_radius, h = 100, center = false);
+        }
+        //
+        // Hole for hot end
+        //
+        translate([filament_x, -extension + eta, filament_z])
+            rotate([90,0,0]) {
+                relief = 0.5;
+
+                translate([0, 0, -insulator_depth + jhead_groove_offset() / 2 + eta])   // slot for the flange
+                    keyhole(insulator / 2, jhead_groove_offset(), width - filament_z);
+
+                *translate([0, 0, -insulator_depth + relief / 2])
+                    keyhole(insulator / 2 + 0.5, relief, width - filament_z);           // relief to avoid corner radius
+                //
+                // Screw holes and nut traps
+                //
+                for(i = [0 : len(jhead_screw_angles) - 1])
+                    rotate([0, 0, jhead_screw_angles[i]])
+                        translate([jhead_screw_pitch, 0, 0])
+                            rotate([0, 0, -jhead_screw_angles[i]]) {
+                                translate([0, 0, washer_thickness(M4_washer) + washer_thickness(M3_washer) - extension_clearance])
+                                    teardrop_plus(r = screw_clearance_radius(jhead_screw), h = jhead_screw_length * 2, center = true);
+
+                                translate([0, 0, jhead_nut_pos - jhead_nut_slot / 2]) {
+                                    w = nut_flat_radius(screw_nut(jhead_screw));
+                                    rotate([0, 0, 90])
+                                        nut_trap(0, nut_radius(screw_nut(jhead_screw)), jhead_nut_slot / 2, horizontal = true);
+
+                                    rotate([0, 0, jhead_screw_angles[i] < 0 ? 180 : 0])
+                                        translate([-w, -1, -jhead_nut_slot / 2])
+                                            cube([w * 2, 100, jhead_nut_slot], center = false);
+                                }
+                            }
+            }
+    }
+}
+
+module extruder_motor_assembly(show_connector = true, exploded = exploded) {
+    assembly("extruder_motor_assembly");
+    // motor and gear
+    translate([-motor_x, motor_z - width / 2, motor_y])
+        rotate([90,0,180]) {
+            rotate([0, 0, 180]) {
+                NEMA(motor);
+
+                translate([0, 0, filament_z - hobbed_offset(pulley)])
+                    rotate([0, 0, -90])
+                        hobbed_pulley_assembly(pulley);
+            }
+            if(show_connector)
+                d_motor_bracket_assembly();
+        }
+    end("extruder_motor_assembly");
+}
+
+module idler_lever_stl() {
+    w = lever_width;
+    h = width - motor_thickness - nut_thickness(M3_nut) - 3 * washer_thickness(M3_washer);
+    h2 = width - idler_z -  ball_bearing_width(idler) / 2 - washer_thickness(M4_washer);
+    //h3 = width - motor_thickness - screw_head_height(M3_cap_screw) - 3 * washer_thickness(M3_washer);
+    h4 = width / 2 - filament_path_r - 0.5;
+    difference() {
+        union() {
+            linear_extrude(height = h, convexity = 10) {
+                union() {
+                    hull() {
+                        circle(ball_bearing_diameter(idler) / 2 - 0.5);                 // idler boss
+
+                        translate([idler_x - idler_pivot_x, idler_pivot_y - idler_y])   // pivot boss
+                            circle(w / 2);
+                    }
+                    hull() {
+                        translate([idler_x - idler_pivot_x, idler_pivot_y - idler_y])   // idler boss
+                            circle(w / 2);
+
+                        translate([idler_x - idler_pivot_x - w / 2, lever_bottom_y - idler_y])    // bottom of lever
+                            square([w, 1]);
+                    }
+                }
+            }
+            *linear_extrude(height = h4)                                                 // release handle
+                hull() {
+                    translate([idler_x - idler_pivot_x, idler_pivot_y - idler_y])
+                        circle(w / 2 - 2);
+
+                    translate([idler_x - idler_pivot_x - 2 * motor_screw_offset, idler_pivot_y - idler_y])
+                        circle(w / 2 - 2);
+                }
+        }
+        translate([0, 0, h2])
+            poly_cylinder(r = ball_bearing_diameter(idler) / 2 + 0.5, h = 10);          // bearing socket
+
+        *translate([idler_x - idler_pivot_x - w / 2 - 1, lever_bottom_y - idler_y - 1, h3])
+            cube([w + 2, 2 * (motor_y - motor_screw_offset - lever_bottom_y) + 1, 10]); // miss the bottom motor screw
+
+        rotate([0, 0, 90])
+            nut_trap(2, nut_trap_radius(M4_nut, horizontal = false, snug = false), nut_trap_depth(M4_nut), supported = true); // nut trap for axle
+
+        translate([idler_x - idler_pivot_x, idler_pivot_y - idler_y, 0])
+            poly_cylinder(r = 3/2, h = 100, center = true);                             // pivot hole
+
+        translate([idler_closed_x - spring_x, spring_y - idler_y, width - spring_z])
+            rotate([90, 0, 90])
+                tearslot(100, M4_clearance_radius, 1, true);                            // Tension screw slot
+
+        translate([idler_x - motor_x,
+                    motor_y - idler_y,
+                    width - (filament_z - hobbed_offset(pulley) + hobbed_screw_z(pulley))])     // clearance for grub screw
+            cylinder(r =grub_screw_clearance_r,
+                     h = 2 * screw_radius(hobbed_screw_type(pulley)) + 1, center = true);
+    }
+}
+
+module direct_idler_assembly() {
+    translate([-idler_x, idler_z - width / 2, idler_y]) {
+        rotate([90, 0, 0]) {
+            translate([0, 0, idler_z - width])
+                color("lime") render() idler_lever_stl();
+
+            ball_bearing(idler)
+                screw(M4_hex_screw, 16);
+
+            translate([0, 0, -ball_bearing_width(idler) / 2])
+                rotate([180, 0, 0])
+                    washer(M4_washer);
+
+            translate([0, 0, idler_z - width + nut_trap_depth(M4_nut)])
+                rotate([180, 0, 90])
+                    nut(M4_nut, true);
+        }
+    }
+
+    translate([-spring_x, spring_z - width / 2, spring_y])
+        rotate([0, 90, 0])
+            washer(M4_washer)
+                comp_spring(spring, compressed_spring)
+                    washer(M4_washer)
+                        screw(M4_cap_screw, 35);
+}
+
+module direct_assembly(show_connector = true, show_drive = true) {
+
+    assembly("extruder_assembly");
+
+    color(wades_block_color) render()
+        difference() {
+            translate([0, -filament_z, 0])
+                rotate([90, 0, 180])
+                    direct_block_stl(false);
+
+            *translate([-1,-10, filament_z])                     // cross section
+                cube([200,100,100]);
+        }
+
+    if(show_drive) {
+        // mounting screws
+        for(side = [-1, 1])
+            translate([filament_x + mount_pitch * side, 0, base_thickness - 3])
+                screw(M4_hex_screw, 20);
+
+        // motor
+        translate([0, 0, 50 * exploded])
+            extruder_motor_assembly(show_connector, 0);
+
+        translate([-motor_x, -width / 2 + motor_thickness, motor_y]) {
+            rotate([-90, 0, 0])
+                NEMA_screws(motor, 3, 8, M3_pan_screw);
+        }
+        translate([-idler_pivot_x,  width / 2, idler_pivot_y])
+            rotate([-90, 0, 0]) {
+                screw_and_washer(M3_cap_screw, 25);
+                translate([0, 0, -(width - motor_thickness)])
+                    washer(M3_washer)
+                        star_washer(M3_washer)
+                            nut(M3_nut)
+                                washer(M3_washer);
+            }
+        //
+        // Filament
+        //
+        color("lime") render() cylinder(r = filament_r, h = 100);
+        //
+        // Idler
+        //
+        direct_idler_assembly();
+
+        translate([-bulkhead_x - bulkhead_depth, spring_z - width / 2, spring_y])
+            rotate([0, 90, 0])
+                nut(M4_nut);
+    }
+
+
+    //
+    // Hot end
+    //
+    assembly("hot_end_assembly");
+    translate([filament_x, 0, -extension])
+        rotate([0, 0, 0]) {
+            if(hot_end_style(hot_end) == m90)
+                m90_hot_end(hot_end);
+            if(hot_end_style(hot_end) == Stoffel)
+                stoffel_hot_end(hot_end);
+            if(hot_end_style(hot_end) == jhead)
+                jhead_hot_end(hot_end, exploded = 0);
+       }
+    end("hot_end_assembly");
+
+    //
+    // Hot end screws
+    //
+    translate([filament_x, 0, -extension])
+        for(i = [0 : len(jhead_screw_angles) - 1]) {
+            a = jhead_screw_angles[i];
+            rotate([180, 0, a]) {
+                translate([jhead_screw_pitch, 0, 0])
+                    washer(jhead_washer)
+                        screw_and_washer(jhead_screw, jhead_screw_length, true);
+
+                translate([jhead_screw_pitch, 0, jhead_nut_pos - jhead_nut_slot / 2 + nut_thickness(screw_nut(jhead_screw)) / 2])
+                    explode([ [ 10 * cos(a),  10 * sin(a), 0],
+                              [ 10 * sin(a), -10 * cos(a), 0],
+                              [-10 * sin(a),  10 * cos(a), 0] ][i])
+                         rotate([180, 0, -a + 90])
+                             nut(screw_nut(jhead_screw));
+            }
+        }
+
+    end("extruder_assembly");
+}
+
+module direct_extruder_stl() {
+    direct_block_stl();
+
+    translate([34, 37, 0])
+        idler_lever_stl();
+}
+
+
+
+if(1)
+    direct_assembly(true);
+else
+    direct_extruder_stl();

scad/main.scad

@@ -30,11 +30,12 @@ use <raspberry_pi.scad>
 use <raspberry_pi_camera.scad>
 use <light_strip.scad>
 include <positions.scad>
+use <x-carriage_assembly.scad>
 
 
 X = 0 * X_travel / 2; // - limit_switch_offset;
 Y = 0 * Y_travel / 2; // - limit_switch_offset;
-Z = 0.5 * Z_travel;
+Z = 0.5 * (Z_travel + limit_switch_offset) - hot_end_bodge(hot_end);
 
 //
 // X axis
@@ -52,7 +53,7 @@ module x_axis_assembly(show_extruder) {
 
     translate([-X + X_origin, 0, Z + Z0 + x_carriage_offset()])
         rotate([180, 0, 180])
-            x_carriage_assembly(show_extruder);
+            x_carriage_assembly(show_extruder, show_fan = true);
 
     color(belt_color)
         translate([0, x_belt_offset(), Z + Z0])

scad/vitamins/hot_ends.scad

@@ -21,6 +21,7 @@ m90_hot_end_12p75mm = [m90,      "HEM90340: Mendel 90 hot end", 57, 10,
 
 JHeadMk4 =            [jhead,   "HEJH16340: JHead MK4 hot end", 64, jhead_inset, 16,    50, "black", 12,            true, 10.19 + 4, [0, 2.94, -5]];
 JHeadMk5 =            [jhead,   "HEJH16340: JHead MK5 hot end", 54, jhead_inset, 16,    40, "black", 12,            true, 9     + 4, [0, 2.38, -5]];
+JHeadMk5x =           [jhead,   "HEJH16340: JHead MK5 hot end", 51.2,jhead_inset,16,    40, "black", 12,            true, 9     + 4, [0, 2.38, -5]];
 
 function hot_end_style(type)              = type[0];
 function hot_end_part(type)               = type[1];
@@ -34,4 +35,11 @@ function hot_end_groove_mount(type)       = type[8];
 function hot_end_duct_radius(type)        = type[9];
 function hot_end_duct_offset(type)        = type[10];
 
+//
+// The actual length of a JHeadMk5 is 51.2 but at the time the kit was designed I thought it was 54. The effect of this is that the
+// extension on the Wades block is shorter than it should be so the tip of the hot end is higher so the fan duct needs to be
+// fitted a bit higher. This bodge allows the model to reflect reality without correcting the extruder block and changing the firmware.
+//
+function hot_end_bodge(type) = type == JHeadMk5 ? 54 - 51.2 : 0;
+
 function hot_end_length(type) = hot_end_total_length(type) - hot_end_inset(type);

scad/vitamins/jhead_hot_end.scad

@@ -6,8 +6,8 @@
 //
 include <../conf/config.scad>
 
-MK4_heater = [ 12.76, 15.88, 8.22, (15.88 / 2 - 4.5), (12.76 / 2 - 0.5 - 2.5 / 2),  (-15.88 / 2 + 5), 9.5];
-MK5_heater = [ 12.76, 12.76, 8.22, (12.76 / 2 - 3.75), (12.76 / 2 - 0.5 - 2.5 / 2), (-12.76 / 2 + 4), 7.5];
+MK4_heater = [ 12.76, 15.88, 8.22, (15.88 / 2 - 4.5), (12.76 / 2 - 0.5 - 2.5 / 2),  (-15.88 / 2 + 5), 9.5, 3];
+MK5_heater = [ 12.76, 12.76, 8.22, (12.76 / 2 - 3.75), (12.76 / 2 - 0.5 - 2.5 / 2), (-12.76 / 2 + 4), 8,   2];
 
 function heater_width(type)  = type[0];
 function heater_length(type) = type[1];
@@ -16,6 +16,7 @@ function resistor_x(type)    = type[3];
 function thermistor_y(type)  = type[4];
 function nozzle_x(type)      = type[5];
 function nozzle_cone(type)   = type[6];
+function nozzle_cone_length(type) = type[7];
 
 barrel_tap_dia = 5;
 
@@ -46,12 +47,13 @@ module heater_block(type, resistor, thermistor) {
 module jhead_hot_end(type, exploded = exploded) {
     resistor = RIE1212UB5C5R6;
     thermistor = Epcos;
-    heater = type == JHeadMk5 ? MK5_heater : MK4_heater;
+    heater = type == JHeadMk4 ? MK4_heater : MK5_heater;
 
     insulator_length = hot_end_insulator_length(type);
     inset = hot_end_inset(type);
-    barrel_length = hot_end_total_length(type) - insulator_length;
-    cone_length = 3;
+    length = hot_end_total_length(type) - hot_end_bodge(type);
+    barrel_length = length - insulator_length;
+    cone_length = nozzle_cone_length(heater);
     cone_end = 1;
     cone_start = nozzle_cone(heater);
     bundle = 3.2;
@@ -61,7 +63,9 @@ module jhead_hot_end(type, exploded = exploded) {
 
     vitamin(hot_end_part(type));
     vitamin("ST25110: 110mm x 25mm self amalgamating silicone tape");
-
+    //
+    // silcone tape
+    //
     color("red")
             if(exploded)
                 translate([0, max(hot_end_insulator_diameter(type) / 2, heater_length(heater) / 2 - nozzle_x(heater)),
@@ -72,12 +76,14 @@ module jhead_hot_end(type, exploded = exploded) {
                     translate([0, 0, + inset - insulator_length])
                         cylinder(r = hot_end_insulator_diameter(type) / 2 + 2 * tape_thickness, h = tape_overlap);
 
-                    translate([0, -nozzle_x(heater), -hot_end_length(type) + cone_length  + 1 + heater_height(heater) / 2 + eta])
+                    translate([0, -nozzle_x(heater), inset - length + cone_length  + 1 + heater_height(heater) / 2 + eta])
                         cube([heater_width(heater) + 4 * tape_thickness,
                               heater_length(heater) + 4 * tape_thickness, heater_height(heater)], center = true);
                 }
-
-    translate([0, 0, inset - insulator_length]) {
+    //
+    // insulator
+    //
+    translate([0, 0, inset - insulator_length])
         color(hot_end_insulator_colour(type)) render(convexity = 10)
             difference() {
                 cylinder(r = hot_end_insulator_diameter(type) / 2, h = insulator_length);
@@ -85,16 +91,18 @@ module jhead_hot_end(type, exploded = exploded) {
                 translate([0, 0, insulator_length - jhead_groove_offset() - jhead_groove() / 2])
                     tube(ir = jhead_groove_dia() / 2, or = 17 / 2, h = jhead_groove());
             }
-
+    //
+    // nozzle
+    //
+    translate([0, 0, inset - length + cone_length])
         color("gold")  render(convexity = 10) union() {
-            translate([0, 0, -barrel_length + cone_length + eta]) {
-                cylinder(r = cone_start / 2, h = barrel_length - cone_length);
-                translate([0, 0, -cone_length + eta])
-                    cylinder(r1 = cone_end / 2, r = cone_start / 2, h = cone_length);
-            }
+            cylinder(r = cone_start / 2, h = barrel_length - cone_length);
+            translate([0, 0, -cone_length + eta])
+                cylinder(r1 = cone_end / 2, r = cone_start / 2, h = cone_length);
         }
-    }
-
+    //
+    // Zip tie and heatshrink
+    //
     rotate([0, 0, 10]) {
         scale([1, (bundle + hot_end_insulator_diameter(type)) / hot_end_insulator_diameter(type)])
                 translate([0, -bundle / 2, -7])
@@ -113,9 +121,11 @@ module jhead_hot_end(type, exploded = exploded) {
     }
     wire("Red PTFE", 16, 170);
     wire("Red PTFE", 16, 170);
-
+    //
+    // heater block
+    //
     rotate([0, 0, 90])
-        translate([-nozzle_x(heater), 0, -hot_end_length(type) + cone_length  + 1 + heater_height(heater) / 2]) {
+        translate([-nozzle_x(heater), 0, inset - length + heater_height(heater) / 2 + cone_length + 1]) {
             heater_block(heater, resistor, thermistor);
 
             intersection() {
@@ -134,4 +144,4 @@ module jhead_hot_end(type, exploded = exploded) {
     }
 }
 
-jhead_hot_end(JHeadMk5);
+jhead_hot_end(hot_end);

scad/wade.scad

@@ -65,7 +65,7 @@ bearing_housing_bulge = driven_x - bearing_housing_x + 1;
 pscrew_length = 50;
 pscrew_x = bearing_housing_x + pscrew_length;
 
-function extruder_connector_offset() = [-filament_x + motor_x, filament_z - thickness, motor_y] + d_motor_connector_offset();
+function wades_extruder_connector_offset() = [-filament_x + motor_x, filament_z - thickness, motor_y] + d_motor_connector_offset();
 
 module keyhole(r, h, l) {
     R = r + layer_height / 4;

scad/x-carriage.scad

@@ -11,32 +11,40 @@
 include <conf/config.scad>
 use <bearing-holder.scad>
 use <wade.scad>
+use <direct.scad>
 
-hole = 36;
-width = hole + 2 * bearing_holder_width(X_bearings);
+function extruder_connector_offset() = extruder == Wades ? wades_extruder_connector_offset() : direct_extruder_connector_offset();
 
-extruder_width = 26;
-function nozzle_x_offset() = 16;                // offset from centre of the extruder
+hole = extruder_hole(extruder);
+width = hole[1] + 2 * bearing_holder_width(X_bearings);
+
+extruder_width = extruder_width(extruder);
+function nozzle_x_offset() = extruder_x_offset(extruder);                // offset from centre of the extruder
 
 
-length = 97;
-top_thickness = 3;
+length = extruder_length(extruder) + 1;
+top_thickness = 2.8;
+min_top_thickness = 2;                                                  // recesses for probe and fan screws
 rim_thickness = 8;
 nut_trap_thickness = 8;
 corner_radius = 5;
-wall = 2; //2.8;
+wall = 2;
+
+nut_flat_rad = squeeze ? nut_trap_flat_radius(M3_nut) : nut_radius(M3_nut);     // bodge for backwards compatibility
 
 base_offset = nozzle_x_offset();      // offset of base from centre
-bar_offset = ceil(max(X_bearings[2] / 2 + rim_thickness + 1,                     // offset of carriage origin from bar centres
-                 nut_radius(M3_nut) * 2 + belt_thickness(X_belt) + pulley_inner_radius + 6 * layer_height));
+bar_offset = ceil(max(bearing_rod_dia(X_bearings) / 2 + rim_thickness + 1,      // z offset of carriage origin from bar centres
+                 nut_flat_rad * 2 + belt_thickness(X_belt) + pulley_inner_radius + 6 * layer_height));
 
-mounting_holes = [[-25, 0], [25, 0], /*[57, 7]*/];
+mounting_holes = [[-25, 0], [25, 0]];
 
 function x_carriage_offset() = bar_offset;
-function x_bar_spacing() = hole + bearing_holder_width(X_bearings);
+function x_bar_spacing() = hole[1] + bearing_holder_width(X_bearings);
 function x_carriage_width() = width;
 function x_carriage_length() = length;
 function x_carriage_thickness() = rim_thickness;
+function x_carriage_top_thickness() = top_thickness;
+function x_carriage_min_top_thickness() = min_top_thickness;
 
 bar_y = x_bar_spacing() / 2;
 bar_x = (length - bearing_holder_length(X_bearings)) / 2;
@@ -49,6 +57,8 @@ lug_depth = X_carriage_clearance + belt_width(X_belt) + belt_clearance + M3_clea
 lug_screw = -(X_carriage_clearance + belt_width(X_belt) + belt_clearance + M3_clearance_radius);
 slot_y =  -X_carriage_clearance - (belt_width(X_belt) + belt_clearance) / 2;
 
+echo(bar_x, zip_x);
+
 function x_carriage_belt_gap() = length - lug_width;
 
 clamp_thickness = 3;
@@ -237,7 +247,7 @@ module x_belt_tensioner_stl()
 }
 
 duct_wall = 2 * 0.35 * 1.5;
-top_thickness = 2;
+duct_top_thickness = 2;
 fan_nut_trap_thickness = 4;
 fan_bracket_thickness = 3;
 
@@ -248,11 +258,11 @@ fan_screw_length = screw_longer_than(fan_depth(part_fan) + fan_bracket_thickness
 fan_width = max(2 * fan_hole_pitch(part_fan) + screw_boss_diameter(fan_screw), fan_bore(part_fan) + 2 * wall);
 fan_screw_boss_r = fan_width / 2 - fan_hole_pitch(part_fan);
 
-front_nut_width = 2 * nut_radius(M3_nut) + wall;
-front_nut_height = 2 * nut_radius(M3_nut) * cos(30) + wall;
-front_nut_depth = wall + nut_trap_depth(M3_nut);
 front_nut_pitch = min((bar_x - bearing_holder_length(X_bearings) / 2 - nut_radius(M3_nut) - 0.3), fan_hole_pitch(part_fan) - 5);
-front_nut_z = 3;
+front_nut_width = 2 * nut_radius(M3_nut) + wall + ((2 * front_nut_pitch < 2 * nut_radius(M3_nut) + 3 * wall) ? wall : 0);
+front_nut_height = 2 * nut_radius(M3_nut) * cos(30) + wall + top_thickness - min_top_thickness;
+front_nut_depth = min(bearing_holder_width(X_bearings) - 2 * wall - nut_thickness(M3_nut, true) - 1, nut_trap_depth(M3_nut) + 6);
+front_nut_z = 5;
 front_nut_y = - width / 2 + wall;
 
 gap = 6;
@@ -264,6 +274,8 @@ or = ir + duct_wall + gap + duct_wall;
 skew = nozzle_height * tan(taper_angle);
 throat_width = (or + skew) * 2;
 
+zip_x = min(length / 2 - lug_width - zipslot_width() / 2 - eta, bar_x);
+
 fan_x = base_offset;
 fan_y = -(width / 2 + fan_width(part_fan) / 2) - (X_carriage_clearance + belt_width(X_belt) + belt_clearance);
 fan_z = nozzle_length + hot_end_duct_offset(hot_end)[2] - duct_height - fan_depth(part_fan) / 2;
@@ -274,7 +286,7 @@ module throat(inner) {
     y = or + skew - duct_wall;
     if(inner)
         translate([-throat_width / 2 + duct_wall, y, nozzle_height])
-            cube([throat_width - 2 * duct_wall, 2 * eta, (duct_height - nozzle_height) - top_thickness]);
+            cube([throat_width - 2 * duct_wall, 2 * eta, (duct_height - nozzle_height) - duct_top_thickness]);
     else
         translate([-throat_width / 2, y - duct_wall, 0])
             cube([throat_width, 2 * eta, duct_height]);
@@ -284,7 +296,7 @@ module neck(inner) {
     iw = 2 * (fan_hole_pitch(part_fan) - fan_screw_boss_r) - 3;
     if(inner)
         translate([fan_x - iw / 2, fan_y_duct - fan_bore(part_fan) / 2, duct_wall])
-            cube([iw, 2 * eta, duct_height - duct_wall - top_thickness]);
+            cube([iw, 2 * eta, duct_height - duct_wall - duct_top_thickness]);
     else
         translate([fan_x - fan_width / 2, fan_y_duct - fan_width / 2, 0])
             cube([fan_width, 2 * eta, duct_height]);
@@ -328,16 +340,16 @@ module x_carriage_fan_duct_stl() {
 
                 // fan entrance
                 hull() {
-                    translate([fan_x, fan_y_duct, duct_wall + duct_height - duct_wall - top_thickness])
+                    translate([fan_x, fan_y_duct, duct_wall + duct_height - duct_wall - duct_top_thickness])
                         rotate([180, 0, 0])
-                            rounded_cylinder(r = fan_bore(part_fan) / 2, h = duct_height - duct_wall - top_thickness, r2 = duct_height / 2);
+                            rounded_cylinder(r = fan_bore(part_fan) / 2, h = duct_height - duct_wall - duct_top_thickness, r2 = duct_height / 2);
 
                     neck(true);
                 }
-                translate([0, 0, duct_height - duct_wall - top_thickness - 1])
+                translate([0, 0, duct_height - duct_wall - duct_top_thickness - 1])
                     hull() {
                         translate([fan_x, fan_y_duct, duct_wall])
-                            cylinder(r = fan_bore(part_fan) / 2, h = duct_height - duct_wall - top_thickness);
+                            cylinder(r = fan_bore(part_fan) / 2, h = duct_height - duct_wall - duct_top_thickness);
 
                         neck(true);
                     }
@@ -384,7 +396,7 @@ module x_carriage_fan_duct_stl() {
         // Cold end cooling vent
         //
         rotate([0, 0, atan2(-fan_x, -fan_y)])
-            translate([0, ir + skew, duct_height - top_thickness - 3])
+            translate([0, ir + skew, duct_height - duct_top_thickness - 3])
                 rotate([90, 0, 0])
                     teardrop(r = 4.5 / 2, h = 10, center = true);
     }
@@ -394,12 +406,19 @@ module x_carriage_fan_bracket_stl() {
     stl("x_carriage_fan_bracket");
 
     t = fan_bracket_thickness;
-    h = fan_z - fan_depth(part_fan) / 2;
+    function local_z(z) = fan_z - fan_depth(part_fan) / 2 - z;  // convert to local z
+
+    belt_x = -length / 2 - tension_screw_pos + tension_screw_length + wall + belt_tensioner_rim_r;
+    belt_z = local_z((x_carriage_offset() - pulley_inner_radius - belt_thickness(X_belt)) / 2);
+
+    screw_z = local_z(front_nut_z);                             // convert to local z
+    h = fan_z - fan_depth(part_fan) / 2;;
     pitch = fan_hole_pitch(part_fan);
     boss_r = washer_diameter(fan_washer) / 2 + 1;
-    w = front_nut_pitch * 2 + washer_diameter(M3_washer) + 2 * t;
+    w = front_nut_pitch * 2 + washer_diameter(M3_washer) + t * 2;
+    crop_w = (belt_x > -w / 2) ? washer_diameter(M3_washer) / 2 - M3_clearance_radius : 0;
     rad = sqrt(2) * pitch - boss_r;
-    bodge = 54 - 51.2;                                              // error in length of MK5 J-head
+    bodge = hot_end_bodge(hot_end);                                   // error in length of MK5 J-head
     dx = pitch - w / 2;
     dy = -(fan_y + width / 2) - pitch;
     hyp = sqrt(dx * dx + dy * dy);
@@ -411,27 +430,34 @@ module x_carriage_fan_bracket_stl() {
     difference() {
         union() {
             hull() {
-                translate([- w / 2, fan_y + width / 2, 0])
-                    cube([w, 1, t]);
+                translate([- w / 2 + crop_w, fan_y + width / 2, 0])
+                    cube([w - crop_w, 1, t]);
 
                 for(side = [-1, 1])
                     translate([side * pitch, -pitch, 0])
                         cylinder(r = boss_r, h = t);
             }
-            translate([- w / 2, fan_y + width / 2, eta])
-                cube([w, t, h]);
+            translate([- w / 2 + crop_w, fan_y + width / 2, eta])
+                cube([w - crop_w, t, h]);
 
             // gussets
             for(side = [-1, 1]) {
-                translate([side * gusset_pitch, fan_y + width / 2 + t - eta, t - eta])
-                    rotate([90, 0, 90])
-                        right_triangle(width = -(fan_y + width / 2 + t) - sqrt(rad * rad - gusset_spacing * gusset_spacing) - eta, height = h - t, h = t);
+                if(gusset_pitch > 0)
+                    translate([side * gusset_pitch, fan_y + width / 2 + t - eta, t - eta])
+                        rotate([90, 0, 90])
+                            right_triangle(width = -(fan_y + width / 2 + t) - sqrt(rad * rad - gusset_spacing * gusset_spacing) - eta, height = h - t, h = t);
+                else
+                    if(2 * front_nut_pitch - washer_diameter(M3_washer) - 1 >= min_wall)
+                        translate([0, fan_y + width / 2 + t - eta, t - eta])
+                            rotate([90, 0, 90])
+                                right_triangle(width = -(fan_y + width / 2 + t) - rad - eta, height = h - t, h = 2 * front_nut_pitch - washer_diameter(M3_washer) - 1);
 
-                translate([side * (w / 2), fan_y + width / 2 + eta, t - eta])
-                    rotate([90, 0, (90 + angle) * side - 90])
-                        translate([0, 0, -side * t / 2])
-                            linear_extrude(height = t, center = true)
-                                polygon([[0, 0], [0, h - t], [t * sin(angle), h - t], [gusset, 0]]);
+                if(side > 0 || !crop_w)
+                    translate([side * (w / 2), fan_y + width / 2 + eta, t - eta])
+                        rotate([90, 0, (90 + angle) * side - 90])
+                            translate([0, 0, -side * t / 2])
+                                linear_extrude(height = t, center = true)
+                                    polygon([[0, 0], [0, h - t], [t * sin(angle), h - t], [gusset, 0]]);
             }
         }
         //
@@ -443,7 +469,7 @@ module x_carriage_fan_bracket_stl() {
             //
             // mounting screw holes
             //
-            translate([side * front_nut_pitch, 0, max(h - top_thickness - front_nut_z - bodge, fan_bracket_thickness + washer_diameter(M3_washer) / 2) + h / 2])
+            translate([side * front_nut_pitch, 0, max(screw_z - bodge, fan_bracket_thickness + washer_diameter(M3_washer) / 2) + h / 2])
                 rotate([90, 0, 0])
                     vertical_tearslot(h = 100, l = h, r = M3_clearance_radius, center = true);
             //
@@ -456,10 +482,10 @@ module x_carriage_fan_bracket_stl() {
 }
 
 bearing_gap = 5;
-bearing_slit = 1;
+bearing_slit = squeeze ? 0.5 : 1;
 
-hole_width = hole - wall - bearing_slit;
-hole_offset = (hole - hole_width) / 2;
+hole_width = hole[1] - wall - bearing_slit;
+hole_offset = (hole[1] - hole_width) / 2;
 
 
 module base_shape() {
@@ -489,21 +515,6 @@ module base_shape() {
     }
 }
 
-module inner_base_shape() {
-    difference() {
-        square([length - 2 * wall, width - 2 * wall], center = true);
-        minkowski() {
-            difference() {
-                square([length + 1, width + 1], center = true);
-                translate([10,0])
-                    square([length + 1, 2 * wall + eta], center = true);
-                base_shape();
-
-            }
-            circle(r = wall, center = true);
-        }
-    }
-}
 
 module x_carriage_stl(){
     stl("x_carriage");
@@ -522,24 +533,24 @@ module x_carriage_stl(){
                                 translate([0, 0, top_thickness])
                                     linear_extrude(height = rim_thickness, center = true, convexity = 5)
                                         difference() {
-                                            inner_base_shape();
-                                            translate([-base_offset, -hole_offset])
-                                                rounded_square(hole + 2 * wall, hole_width + 2 * wall, corner_radius + wall);
+                                            offset(-wall)
+                                                base_shape();
 
+                                            translate([-base_offset, -hole_offset])
+                                                rounded_square(hole[0] + 2 * wall, hole_width + 2 * wall, hole[2] + wall);
                                         }
                             }
                             // ribs between bearing holders
-                            for(side = [-1,1])
-                                assign(rib_height = bar_offset - X_bar_dia / 2 - 2)
+                            for(side = [-1,1]) {
+                                rib_height = bar_offset - X_bar_dia / 2 - 2;
                                 translate([0, - bar_y + side * (bearing_holder_width(X_bearings) / 2 - (wall + eta) / 2), rib_height / 2 - top_thickness + eta])
                                     cube([2 * bar_x - bearing_holder_length(X_bearings) + eta, wall + eta, rib_height], center = true);
-
+                            }
                             // Front nut traps for large fan mount
                             for(end = [-1, 1])
                                 translate([end * (bar_x - bearing_holder_length(X_bearings) / 2 - front_nut_width / 2 + eta) - front_nut_width / 2,
                                             -width / 2 + wall, -top_thickness - eta])
                                      cube([front_nut_width, front_nut_depth, front_nut_height]);
-
                          }
                         //Holes for bearing holders
                         translate([0,        bar_y, rim_thickness - top_thickness - eta])
@@ -573,15 +584,16 @@ module x_carriage_stl(){
                         belt_lug(false);
 
                 //Bearing holders
-                translate([0,        bar_y, bar_offset - top_thickness]) rotate([0,0,90]) bearing_holder(X_bearings, bar_offset - eta);
-                translate([- bar_x, -bar_y, bar_offset - top_thickness]) rotate([0,0,90]) bearing_holder(X_bearings, bar_offset - eta);
-                translate([+ bar_x, -bar_y, bar_offset - top_thickness]) rotate([0,0,90]) bearing_holder(X_bearings, bar_offset - eta);
+                for(end = [-1, 0, 1])
+                    translate([end * bar_x, end ? -bar_y : bar_y, bar_offset - top_thickness])
+                        rotate([0, 0, 90])
+                            bearing_holder(X_bearings, bar_offset - eta, tie_offset = end * (zip_x - bar_x));
 
             }
             translate([-base_offset, 0, 0]) {
                 // hole to clear the hot end
                 translate([0, - hole_offset])
-                    rounded_rectangle([hole, hole_width, 2 * rim_thickness], corner_radius);
+                    rounded_rectangle([hole[0], hole_width, 2 * rim_thickness], hole[2]);
 
                 // holes for connecting extruder
                 for(xy = mounting_holes)
@@ -599,12 +611,13 @@ module x_carriage_stl(){
             //
             for(end = [-1, 1])
                 translate([end * front_nut_pitch,
-                           -width / 2 + front_nut_depth,
-                           front_nut_z])
+                           -width / 2 + wall + front_nut_depth,
+                           front_nut_z - top_thickness])
                     rotate([90, 0, 0])
                         intersection() {
-                            nut_trap(screw_clearance_radius(M3_cap_screw), M3_nut_radius, M3_nut_trap_depth, true);
-                            cylinder(r = M3_nut_radius + 1, h = bearing_holder_width(X_bearings), center = true);
+                            nut_trap(screw_clearance_radius(M3_cap_screw), M3_nut_radius, front_nut_depth, true);
+                            translate([0, 0, -(bearing_holder_width(X_bearings) - 2 * wall - front_nut_depth - 2 * eta)])
+                                cylinder(r = M3_nut_radius + 1, h = 100);
                         }
         }
 }
@@ -625,7 +638,7 @@ module x_carriage_fan_assembly() {
                         screw_and_washer(fan_screw, fan_screw_length);
             fan_hole_positions(part_fan) group() {
                 rotate([180, 0, 0])
-                    translate([0, 0, fan_depth(part_fan) + top_thickness + 30 * exploded])
+                    translate([0, 0, fan_depth(part_fan) + duct_top_thickness + 30 * exploded])
                         nut(fan_nut, true);
             }
             translate([0, 0, fan_depth(part_fan) / 2])
@@ -635,97 +648,6 @@ module x_carriage_fan_assembly() {
     end("x_carriage_fan_assembly");
 }
 
-module x_carriage_assembly(show_extruder = true, show_fan = true) {
-    if(show_extruder) {
-        translate([75, extruder_width / 2, eta])
-            rotate([-90,0,180])
-                wades_assembly();
-
-        for(end = [-1, 1])
-            translate([25 * end, 0, nut_trap_thickness])
-                rotate([0, 0, 45])
-                    wingnut(M4_wingnut);
-    }
-    //
-    // Fan assembly
-    //
-    if(show_fan)
-        x_carriage_fan_assembly();
-
-    assembly("x_carriage_assembly");
-    color(x_carriage_color) render() x_carriage_stl();
-    //
-    // Fan bracket screws
-    //
-    for(side = [-1, 1])
-        translate([fan_x + side * front_nut_pitch, -width / 2 - fan_bracket_thickness, front_nut_z + top_thickness]) {
-            rotate([90, 0, 0])
-                screw_and_washer(M3_cap_screw, 10);
-
-            translate([0, fan_bracket_thickness + wall, 0])
-                rotate([-90, 0, 0])
-                    nut(M3_nut, true);
-        }
-
-    translate([base_offset, bar_y, bar_offset]) {
-        linear_bearing(X_bearings);
-        rotate([0,-90,0])
-            scale([bearing_radius(X_bearings) / bearing_ziptie_radius(X_bearings), 1])
-                ziptie(small_ziptie, bearing_ziptie_radius(X_bearings));
-    }
-    for(end = [-1,1])
-        translate([base_offset + bar_x * end, -bar_y, bar_offset]) {
-            linear_bearing(X_bearings);
-            rotate([90,-90,90])
-                scale([bearing_radius(X_bearings) / bearing_ziptie_radius(X_bearings), 1])
-                    ziptie(small_ziptie, bearing_ziptie_radius(X_bearings));
-        }
-    //
-    // Idler end belt clamp
-    //
-    translate([length / 2 + base_offset, -width / 2, x_carriage_offset() - ball_bearing_diameter(X_idler_bearing) / 2]) {
-        mirror([1,0,0])
-            color(x_belt_clamp_color) render() x_belt_clamp_stl();
-        translate([-lug_width / 2, lug_screw, clamp_thickness])
-            nut(M3_nut, true);
-    }
-
-    translate([length / 2 + base_offset - lug_width / 2, -width / 2 + lug_screw, 0])
-        rotate([180, 0, 0])
-            screw_and_washer(M3_cap_screw, 20);
-    //
-    // Motor end belt clamp
-    //
-    translate([-length / 2 + base_offset, -width / 2, x_carriage_offset() - pulley_inner_radius])
-        translate([lug_width / 2, lug_screw, clamp_thickness])
-            nut(M3_nut, true);
-
-    translate([-length / 2 + base_offset, -width / 2, -(clamp_thickness + belt_thickness(X_belt))]) {
-        color(x_belt_clamp_color) render() x_belt_grip_stl();
-        translate([lug_width / 2, lug_screw, 0])
-            rotate([180, 0, 0])
-                screw_and_washer(M3_cap_screw, 25);
-    }
-
-    translate([-length / 2 + base_offset - tension_screw_pos, -width / 2 + slot_y, (x_carriage_offset() - pulley_inner_radius - belt_thickness(X_belt)) /2]) {
-        rotate([0, -90, 0])
-            screw(M3_cap_screw, tension_screw_length);    // tensioning screw
-
-        translate([tension_screw_length + wall, belt_tensioner_height / 2, 0])
-            rotate([90, 180, 0])
-                color(x_belt_clamp_color) render() x_belt_tensioner_stl();
-
-        translate([tension_screw_length + wall, 0, 0])
-            rotate([90, 180, 0])
-                belt_loop();
-    }
-
-    translate([-length / 2 + base_offset + lug_width - M3_nut_trap_depth, -width / 2 + slot_y, (x_carriage_offset() - pulley_inner_radius - belt_thickness(X_belt)) /2])
-        rotate([90, 0, 90])
-            nut(M3_nut, false);   // tensioning nut
-
-    end("x_carriage_assembly");
-}
 
 module x_carriage_parts_stl() {
     x_carriage_stl();
@@ -742,19 +664,3 @@ module x_carriage_fan_ducts_stl() {
         rotate([0, 0, 180])
             x_carriage_fan_duct_stl();
 }
-
-if(0)
-    if(0)  {
-        intersection() {
-            x_carriage_fan_duct_stl();
-            *translate([0, 0, -10])
-                cube(200);
-        }
-    }
-    else
-        if(0)
-            x_carriage_fan_ducts_stl();
-        else
-            x_carriage_parts_stl();
-else
-    x_carriage_assembly(true);

scad/x-carriage_assembly.scad

@@ -0,0 +1,122 @@
+//
+// Mendel90
+//
+// GNU GPL v2
+// nop.head@gmail.com
+// hydraraptor.blogspot.com
+//
+// X carriage, carries the extruder
+//
+
+include <x-carriage.scad>
+
+module x_carriage_assembly(show_extruder = true, show_fan = true) {
+    if(show_extruder) {
+        if(extruder == Wades)
+            translate([75, extruder_width / 2, eta])
+                rotate([-90,0,180])
+                    wades_assembly();
+
+        if(extruder == Direct14)
+            rotate([180, 0, 180])
+                direct_assembly();
+
+        for(end = [-1, 1])
+            translate([extruder_mount_pitch / 2 * end, 0, nut_trap_thickness])
+                rotate([0, 0, 45])
+                    wingnut(M4_wingnut);
+    }
+    //
+    // Fan assembly
+    //
+    if(show_fan)
+        translate([0, 0, -hot_end_bodge(hot_end)])
+            x_carriage_fan_assembly();
+
+    assembly("x_carriage_assembly");
+    color(x_carriage_color) render() x_carriage_stl();
+    //
+    // Fan bracket screws
+    //
+    for(side = [-1, 1])
+        translate([fan_x + side * front_nut_pitch, -width / 2 - fan_bracket_thickness, front_nut_z]) {
+            rotate([90, 0, 0])
+                screw_and_washer(M3_cap_screw, 16);
+
+            translate([0, fan_bracket_thickness + wall, 0])
+                rotate([-90, 0, 0])
+                    nut(M3_nut, true);
+        }
+    //
+    // Bearings
+    //
+    for(end = [-1, 0, 1])
+        translate([base_offset + bar_x * end, end ? -bar_y : bar_y, bar_offset]) {
+            linear_bearing(X_bearings);
+            translate([end * (zip_x - bar_x), 0, 0])
+                rotate([0, -90, end ? 180 : 0])
+                    scale([bearing_radius(X_bearings) / bearing_ziptie_radius(X_bearings), 1])
+                        ziptie(small_ziptie, bearing_ziptie_radius(X_bearings));
+        }
+    //
+    // Idler end belt clamp
+    //
+    translate([length / 2 + base_offset, -width / 2, x_carriage_offset() - ball_bearing_diameter(X_idler_bearing) / 2]) {
+        mirror([1,0,0])
+            color(x_belt_clamp_color) render() x_belt_clamp_stl();
+        translate([-lug_width / 2, lug_screw, clamp_thickness])
+            nut(M3_nut, true);
+    }
+
+    translate([length / 2 + base_offset - lug_width / 2, -width / 2 + lug_screw, 0])
+        rotate([180, 0, 0])
+            screw_and_washer(M3_cap_screw, 20);
+    //
+    // Motor end belt clamp
+    //
+    translate([-length / 2 + base_offset, -width / 2, x_carriage_offset() - pulley_inner_radius])
+        translate([lug_width / 2, lug_screw, clamp_thickness])
+            nut(M3_nut, true);
+
+    translate([-length / 2 + base_offset, -width / 2, -(clamp_thickness + belt_thickness(X_belt))]) {
+        color(x_belt_clamp_color) render() x_belt_grip_stl();
+        translate([lug_width / 2, lug_screw, 0])
+            rotate([180, 0, 0])
+                screw_and_washer(M3_cap_screw, 25);
+    }
+
+    translate([-length / 2 + base_offset - tension_screw_pos, -width / 2 + slot_y, (x_carriage_offset() - pulley_inner_radius - belt_thickness(X_belt)) /2]) {
+        rotate([0, -90, 0])
+            screw(M3_cap_screw, tension_screw_length);    // tensioning screw
+
+        translate([tension_screw_length + wall, belt_tensioner_height / 2, 0])
+            rotate([90, 180, 0])
+                color(x_belt_clamp_color) render() x_belt_tensioner_stl();
+
+        translate([tension_screw_length + wall, 0, 0])
+            rotate([90, 180, 0])
+                belt_loop();
+    }
+
+    translate([-length / 2 + base_offset + lug_width - M3_nut_trap_depth, -width / 2 + slot_y, (x_carriage_offset() - pulley_inner_radius - belt_thickness(X_belt)) /2])
+        rotate([90, 0, 90])
+            nut(M3_nut, false);   // tensioning nut
+
+    end("x_carriage_assembly");
+}
+
+if(0)
+    if(0)  {
+        intersection() {
+            x_carriage_fan_duct_stl();
+            *translate([0, 0, -10])
+                cube(200);
+        }
+    }
+    else
+        if(0)
+            x_carriage_fan_ducts_stl();
+        else
+            x_carriage_parts_stl();
+else
+    x_carriage_assembly(true, true);