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https://github.com/nophead/Mendel90.git
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542 lines
19 KiB
OpenSCAD
542 lines
19 KiB
OpenSCAD
//
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// Mendel90
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//
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// GNU GPL v2
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// nop.head@gmail.com
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// hydraraptor.blogspot.com
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//
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// Originally based on Josef Prusa's version but much hacked
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//
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include <conf/config.scad>
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use <d-motor_bracket.scad>
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use <hot_end.scad>
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spring = false; // use two nuts or one nut and a spring
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screw_depth = 5;
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motor = extruder_motor(extruder);
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motor_y = 28;
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motor_min = 26 + 5;
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motor_max = 36;
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motor_x = (motor_min + motor_max) / 2;
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motor_leeway = motor_max - motor_min;
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thickness = 5;
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base_thickness = 6;
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width = 26;
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height = 52;
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filament_x = 75;
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filament_z = 13;
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feed_tube_socket = 4;
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extension_clearance = hot_end_style(hot_end) == e3d ? 0.5 : 1;
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extension = max(extension_clearance, nozzle_length(hot_end) - hot_end_length(hot_end));
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extension_width = 30;
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jhead_screw = M3_cap_screw;
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jhead_washer = M4_washer;
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jhead_screw_length = screw_longer_than(
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extension +
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base_thickness +
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nut_thickness(screw_nut(jhead_screw)) +
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washer_thickness(screw_washer(jhead_screw)) +
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washer_thickness(jhead_washer)
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);
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jhead_screw_pitch = max(hot_end_insulator_diameter(hot_end) / 2 + screw_head_radius(jhead_screw),
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hot_end_groove_dia(hot_end) / 2 + washer_diameter(jhead_washer) / 2);
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extension_rad = jhead_screw_pitch + 5;
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pscrew_y = [17.5, 45.5];
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pscrew_z = [filament_z - 6.5, filament_z + 6.5];
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driven_x = 70;
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driven_y = 31.5;
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bearing = BB608;
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bearing_rad = ball_bearing_diameter(bearing) / 2;
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socket_rad = bearing_rad; // make it a tight fit
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socket_cr = corrected_radius(socket_rad); // actual radius
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bearing_housing_x = 57;
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bearing_housing_x2 = driven_x + socket_cr + 2 * filament_width;
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bearing_housing_depth = bearing_housing_x2 - bearing_housing_x;
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bearing_housing_bulge = driven_x - bearing_housing_x + 1;
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pscrew_length = 50;
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pscrew_x = bearing_housing_x + pscrew_length;
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function wades_extruder_connector_offset() = [-filament_x + motor_x, filament_z - thickness, motor_y] + d_motor_connector_offset();
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module keyhole(r, h, l) {
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R = r + layer_height / 4;
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waist = 2 * R - 1;
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entrance = 2 * R + 0.5;
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y = sqrt(R * R - waist * waist / 4);
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teardrop(h = h, r = R, center = true);
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*hull() {
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translate([0, l, 0])
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cube([entrance, 2 * eta, h ], center = true);
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translate([0, y, 0])
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cube([waist, 2 * eta, h ], center = true);
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}
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}
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nut_inset = min_wall;
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jhead_screw_angle = 5;
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jhead_nut_slot = nut_thickness(screw_nut(jhead_screw)) + 0.3;
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module wades_block_stl() {
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stl("wades_block");
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insulator = hot_end_insulator_diameter(hot_end);
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screw_pitch = hot_end_screw_pitch(hot_end);
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insulator_depth = hot_end_inset(hot_end);
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nut_clearance = 2 * nut_thickness(M4_nut);
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nut_slot = nut_thickness(M4_nut) + 0.3;
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difference(){
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union(){
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cube([81, height, thickness]); // motor plate
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cube([filament_x + 25 - 3.5, base_thickness, width]); // base
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translate([filament_x + 25 - 3.5, base_thickness / 2, filament_z])
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intersection() {
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union() {
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for(a = [-90, 90])
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rotate([a, 0, 0])
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teardrop(r = 10.6, h = base_thickness, truncate = false, center = true);
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}
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cube([22, base_thickness + 1, width], center = true);
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}
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translate([bearing_housing_x, 0, 0])
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cube([bearing_housing_depth, height, width]); // bearing housing
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translate([driven_x + 6, driven_y, 0])
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difference() {
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cylinder(r = bearing_housing_bulge + 6, h = width); // bulge to make it stronger
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translate([0, -25, -1])
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cube([50, 50, width + 2]);
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}
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translate([80,1.5,0]) // fillet
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cube([11,11, width]);
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if(extension)
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translate([filament_x - extension_width / 2, -extension + extension_clearance + eta, 0])
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intersection() {
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cube([extension_width, extension - extension_clearance, width]);
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translate([extension_width / 2, extension / 2, filament_z])
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rotate([-90, 0, 0])
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teardrop(r = extension_rad, h = extension + 1, center = true);
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}
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}
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translate([-11,-1,30]) rotate([0,60,0]) cube([30, base_thickness + 2, 60]); // slope on base
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translate([filament_x, 20, filament_z])
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rotate([90,0,0])
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teardrop_plus(h = 70, r = (extruder_filament(extruder) + 0.5) / 2, center=true); // filament
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translate([filament_x, height, filament_z])
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rotate([90,0,0])
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teardrop_plus(h = feed_tube_socket * 2, r = tubing_od(PF7) / 2, center = true); // feed tube socket
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// mounting holes
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translate([filament_x, base_thickness, filament_z])
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extruder_mounting_holes();
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// pressure screws
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for(i = [0, 1]) {
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translate([bearing_housing_x + nut_inset + nut_slot / 2, pscrew_y[i], pscrew_z[i]]) {
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rotate([-90, 90, 90])
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nut_trap(0, M4_nut_radius, nut_slot / 2, true);
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rotate([180 + 180 * i, 0, 0])
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translate([0, 0, 5])
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cube([nut_slot, nut_flat_radius(M4_nut) * 2, 10], center = true);
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}
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translate([bearing_housing_x - 4, pscrew_y[i], pscrew_z[i]])
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rotate([90,0,90])
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teardrop(h = bearing_housing_depth + 10, r = 4.4 / 2);
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}
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//
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// holes for motor
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//
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translate([motor_x, motor_y, -1]) {
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slot(r = NEMA_big_hole(motor), l = motor_leeway, h = 10, center = false); // motor hub slot
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for(x = NEMA_holes(motor)) // motor screw slots
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for(y = NEMA_holes(motor))
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translate([x,y,0])
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slot(r = M3_clearance_radius, l = motor_leeway, h = 10, center = false);
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}
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//
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// remove fourth motor slot
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//
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translate([motor_x - 40 + motor_leeway / 2, motor_y - NEMA_big_hole(motor), -1])
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cube([40, 32, 7]);
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translate([motor_x - 40 + motor_leeway / 2 + 6, motor_y, -1])
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cube([40, 32, 7]);
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translate([-1,-1,-1]) cube([12,60,30]); // truncates tail
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translate([11, 0, -1])
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fillet(4, 30);
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translate([11, motor_y - NEMA_big_hole(motor), -1])
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rotate([0, 0, -90])
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fillet(4, 30);
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translate([motor_x + motor_leeway / 2 + 6, height, -1])
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rotate([0, 0, -90])
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fillet(4, 30);
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//
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// hole for hobbed bolt
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//
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difference() {
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translate([driven_x, driven_y, 7 + layer_height + eta])
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poly_cylinder(r = M8_clearance_radius + 0.25, h = 30);
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translate([driven_x + 1.9, driven_y - 5, filament_z + 4 ])
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cube([10, 10, layer_height]); // support bridge
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}
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//
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// Sockets for bearings
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//
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translate([driven_x, driven_y, width - 7]) poly_cylinder(r = socket_rad, h = 8); // top bearing socket
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translate([filament_x + 8, driven_y, filament_z - 4]) cylinder(r = bearing_rad, h = 8); // clearance for idler
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translate([driven_x, driven_y, -1 + eta]) poly_cylinder(r = socket_rad, h = 8); // bottom bearing socket
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//
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// Hole for hot end
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//
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translate([filament_x, -extension + eta, filament_z])
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rotate([90,0,0]) {
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if(hot_end_groove(hot_end)) {
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relief = 0.5;
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translate([0, 0, -insulator_depth + hot_end_inset(hot_end) / 2 + eta]) // slot for the flange
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keyhole(insulator / 2, hot_end_inset(hot_end), width - filament_z);
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translate([0, 0, -insulator_depth + relief / 2])
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keyhole(insulator / 2 + 0.5, relief, width - filament_z); // relief to avoid corner radius
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//
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// Screw holes and nut traps
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//
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for(i = [0:2])
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rotate([0, 0, i * 120 + jhead_screw_angle])
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translate([jhead_screw_pitch, 0, 0])
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rotate([0, 0, -i * 120 - jhead_screw_angle]) {
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w = nut_flat_radius(screw_nut(jhead_screw));
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teardrop_plus(r = screw_clearance_radius(jhead_screw), h = jhead_screw_length * 2, center = true);
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translate([0, 0, -base_thickness - extension - jhead_nut_slot / 2]) {
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rotate([0, 0, [0, 30, 30][i]])
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nut_trap(0, nut_radius(screw_nut(jhead_screw)), jhead_nut_slot / 2, horizontal = true);
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rotate([0, 0, [-90 ,0, 180][i]])
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translate([-w, 0, -jhead_nut_slot / 2])
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cube([w * 2, 100, jhead_nut_slot], center = false);
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}
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}
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}
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else {
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teardrop_plus(h = insulator_depth * 2, r = insulator / 2, center = true); // insulator socket
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translate([0, 0, -insulator_depth + 0.5])
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teardrop_plus(h = 1 , r = insulator / 2 + 1, center=true); // relief to avoid radius so end is flat
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}
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}
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if(!hot_end_groove(hot_end))
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for(side = [-1, 1])
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translate([filament_x + screw_pitch * side, screw_depth - extension, -1])
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rotate([0, 0, -90 + 90 * side])
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poly_cylinder(h = 30, r = M3_clearance_radius); // retaining screws
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}
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}
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spacer_length = 4 * 1.5;
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gear_thickness = 6;
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module wades_gear_spacer_stl() {
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stl("wades_gear_spacer");
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washer = M8_washer;
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difference() {
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cylinder(r = washer_diameter(washer) / 2, h = spacer_length, center = false);
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translate([0,0, -0.5])
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poly_cylinder(r = M8_clearance_radius, h = spacer_length + 1, center = false);
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}
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}
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module wades_big_gear_stl() {
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stl("wades_big_gear");
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color(wades_big_gear_color) difference() {
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import("../imported_stls/39t17p.stl", convexity = 10);
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poly_cylinder(r = 4, h = 100, center = true);
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}
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}
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module wades_small_gear_stl() {
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stl("wades_small_gear");
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color(wades_small_gear_color) difference() {
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translate([-10, -10, 0])
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import("../imported_stls/wades_gear.stl", convexity = 10);
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translate([0, 0, 4])
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rotate([90, 0, -24 + 180])
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teardrop_plus(r = M3_clearance_radius, h = 100);
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}
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}
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module small_gear_assembly() {
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wades_small_gear_stl();
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rotate([90, 0, -24]) {
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translate([0, 4, -5/2 - 6])
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rotate([180, 0, 0])
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screw(M3_grub_screw, 6);
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translate([0, 4, -6])
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explode([0, -10 ,0])
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rotate([0,0,30])
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nut(M3_nut);
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}
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}
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idler_height = 12;
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idler_axel_length = 22;
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idler_axel_slot = idler_axel_length + 2;
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idler_short_side = idler_axel_slot + 2 * min_wall;
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module wades_idler_block_stl() {
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stl("wades_idler_block");
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long_side = 37;
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corners_diameter = 3;
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608_dia = 12;
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608_height = 9;
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mounting_dia = 4.5;
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difference(){
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// Main block
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rounded_rectangle([long_side, idler_short_side, idler_height], corners_diameter, center = false);
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// bearing cutout
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translate([0, 0, idler_height - 2]){
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rotate([90,0,0])
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cylinder(h = 608_height, r=608_dia, center=true);
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rotate(a=[90,0,0])
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cylinder(h = idler_axel_slot, r=8.6/2, center=true);
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}
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//mounting holes
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for(i = [0,1])
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translate([pscrew_y[1-i] - driven_y, pscrew_z[i] - filament_z, 0])
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poly_cylinder(h = idler_height * 2.1, r = mounting_dia / 2, center=true);
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}
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}
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module wade_idler_assembly() {
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color(wades_idler_block_color) render() wades_idler_block_stl();
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translate([0, 0, idler_height - 2])
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rotate([90, 0, 0]) {
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rod(d = 8, l = idler_axel_length);
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ball_bearing(bearing);
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}
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}
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module wades_motor_assembly(show_connector = true, exploded = exploded) {
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assembly("extruder_motor_assembly");
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// motor and gear
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rotate([0, 0, 180])
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NEMA(motor);
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translate([0,0, 2.5 + 30 * exploded])
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rotate([0, 0, 11])
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small_gear_assembly();
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if(show_connector)
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d_motor_bracket_assembly();
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end("extruder_motor_assembly");
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}
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module wades_assembly(show_connector = true, show_drive = true) {
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spring_total = 10;
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spring_length = spring_total - 2 * washer_thickness(M4_washer);
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assembly("extruder_assembly");
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translate([-filament_x, width / 2, eta])
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rotate([90,0,0]) {
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color(wades_block_color) render()
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difference() {
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wades_block_stl();
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*translate([-1,-10, filament_z]) // cross section
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cube([200,100,100]);
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}
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if(show_drive) {
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// idler screws, washers and springs
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for(i = [0,1])
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translate([pscrew_x, pscrew_y[i], pscrew_z[i]])
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rotate([90, 90, 90]) {
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screw(M4_hex_screw, pscrew_length);
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translate([0,0, -pscrew_length + nut_inset])
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explode([12 - 24 * i, 0, 0])
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nut(M4_nut);
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translate([0, 0, -spring_total + 53 * exploded]) {
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washer(M4_washer)
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comp_spring(extruder_spring, spring_length)
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washer(M4_washer);
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}
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}
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// mounting screws
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translate([filament_x, base_thickness, filament_z])
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rotate([-90, 0, 0])
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extruder_mounting_screws();
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//idler
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translate([filament_x + 22 + 39 * exploded, driven_y, filament_z])
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rotate([90, 0, -90])
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wade_idler_assembly();
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// motor
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translate([0, 0, 50 * exploded])
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translate([motor_x, motor_y, thickness + eta])
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rotate([0,180,0])
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wades_motor_assembly(show_connector, 0);
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translate([motor_x, motor_y, 0])
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rotate([0, 180, -90])
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NEMA_screws(motor, 3, 10, M3_hex_screw);
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}
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// hobbed bolt and gear
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translate([driven_x, driven_y, 0]) {
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translate([0, 0, width - ball_bearing_width(bearing) / 2 + (!show_drive ? exploded * 20 : 0)])
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ball_bearing(bearing);
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translate([0, 0, ball_bearing_width(bearing) / 2 - (!show_drive ? exploded * 20 : 0)])
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ball_bearing(bearing);
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if(show_drive) {
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translate([0, 0, - 30 * exploded])
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rotate([180, 0, 0])
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color(wades_gear_spacer_color) render() wades_gear_spacer_stl();
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translate([0, 0, -spacer_length - 50 * exploded])
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rotate([180, 0, 0])
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wades_big_gear_stl();
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translate([0,0, -spacer_length - gear_thickness])
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rotate([180, 0, 0])
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screw(M8_hex_screw, 60, spacer_length + gear_thickness + filament_z);
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translate([0,0, width]) {
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if(spring) {
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comp_spring(hob_spring, 8);
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translate([0, 0, 8])
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nut(M8_nut);
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}
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else explode([0, 0, 35]) group() {
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translate([0, 0, -15 * exploded])
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nut(M8_nut);
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translate([0, 0, nut_thickness(M8_nut) - 10 * exploded]) {
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star_washer(M8_washer);
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translate([0, 0, washer_thickness(M8_washer) + 5 * exploded])
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nut(M8_nut);
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}
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}
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}
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}
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|
}
|
|
|
|
//
|
|
// Hot end
|
|
//
|
|
translate([filament_x, -extension, filament_z])
|
|
rotate([-90, 0, 0])
|
|
hot_end_assembly();
|
|
|
|
if(!hot_end_groove(hot_end))
|
|
for(side = [-1, 1])
|
|
translate([filament_x + hot_end_screw_pitch(hot_end) * side, screw_depth - extension, width])
|
|
screw(M3_cap_screw, 30);
|
|
else
|
|
translate([filament_x, -extension, filament_z])
|
|
for(i = [0:2]) {
|
|
a = i * 120 - jhead_screw_angle;
|
|
rotate([90, a, 0]) {
|
|
translate([jhead_screw_pitch, 0, 0])
|
|
washer(jhead_washer)
|
|
star_washer(screw_washer(jhead_screw))
|
|
screw(jhead_screw, jhead_screw_length);
|
|
|
|
translate([jhead_screw_pitch, 0, -extension - base_thickness - 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([0, 0, [0, 30, 30][i]])
|
|
nut(screw_nut(jhead_screw));
|
|
}
|
|
}
|
|
}
|
|
end("extruder_assembly");
|
|
}
|
|
|
|
module wades_extruder_stl() {
|
|
difference() {
|
|
wades_block_stl();
|
|
*translate([0, driven_y, -1])
|
|
cube([100,30,100]);
|
|
}
|
|
translate([97, driven_y + 1, 0]) rotate([0,0,90]) wades_idler_block_stl();
|
|
translate([motor_max, motor_y, 0]) wades_gear_spacer_stl();
|
|
}
|
|
|
|
module wades_big_gear_x5_stl(){
|
|
|
|
pitch = 44;
|
|
wades_big_gear_stl();
|
|
for(x = [-1,1])
|
|
for(y = [-1,1])
|
|
translate([x * pitch, y * pitch, 0])
|
|
wades_big_gear_stl();
|
|
}
|
|
|
|
|
|
if(1)
|
|
wades_assembly(true);
|
|
else
|
|
if(1)
|
|
wades_extruder_stl();
|
|
else
|
|
wades_big_gear_x5_stl();
|