Merge branch 'martinbudden-green_terminals'

Unexploded assembly view shows round screw holes to represent the tapped state.

libtest.scad

@@ -118,6 +118,7 @@ use <tests/foot.scad>
 use <tests/handle.scad>
 use <tests/PCB_mount.scad>
 use <tests/printed_box.scad>
+use <tests/printed_pulleys.scad>
 use <tests/ribbon_clamp.scad>
 use <tests/screw_knob.scad>
 use <tests/socket_box.scad>
@@ -170,6 +171,9 @@ translate([x5, cable_grommets_y + 370])
 translate([x5 + 60, cable_grommets_y + 200])
     strap_handles();
 
+translate([640, cable_grommets_y + 200])
+    printed_pulley_test();
+
 translate([x5, cable_grommets_y + 250])
     handle();
 

printed/drag_chain.scad

@@ -251,7 +251,7 @@ module drag_chain_link(type, start = false, end = false, check_kids = true) { //
 }
 
 // Need to use a wrapper because can't define nested modules in an assembly
-module _drag_chain_assembly(type, pos = 0) {
+module _drag_chain_assembly(type, pos = 0, render = false) {
     s = drag_chain_size(type);
     x = (1 + exploded()) * s.x;
     r = drag_chain_radius(type) * x / s.x;
@@ -278,8 +278,11 @@ module _drag_chain_assembly(type, pos = 0) {
     module link(n)                                  // Position and colour link with origin at the hinge hole
         translate([-z / 2, 0, -z / 2]) {
             stl_colour(n < 0 || n == npoints - 1 ? pp3_colour : n % 2 ? pp1_colour : pp2_colour)
-                drag_chain_link(type, start = n == -1, end = n == npoints - 1, check_kids = false)
-                    let($fasteners = 0) children();
+                render_if(render)
+                    drag_chain_link(type, start = n == -1, end = n == npoints - 1, check_kids = false)
+                        let($fasteners = 0)
+                            children();
+
             let($fasteners = 1) children();
         }
 
@@ -307,15 +310,15 @@ module _drag_chain_assembly(type, pos = 0) {
 
 //! 1. Remove the support material from the links with side cutters.
 //! 1. Clip the links together with the special ones at the ends.
-module drag_chain_assembly(type, pos = 0)  //! Drag chain assembly
+module drag_chain_assembly(type, pos = 0, render = false)  //! Drag chain assembly
     assembly(str(drag_chain_name(type), "_drag_chain"), big = true)
         if($children == 2)
-            _drag_chain_assembly(type, pos) {
+            _drag_chain_assembly(type, pos, render) {
                 children(0);
                 children(1);
             }
         else if($children == 1)
-            _drag_chain_assembly(type, pos)
+            _drag_chain_assembly(type, pos, render)
                 children(0);
         else
-            _drag_chain_assembly(type, pos);
+            _drag_chain_assembly(type, pos, render);

printed/printed_pulleys.scad

@@ -0,0 +1,200 @@
+//
+// NopSCADlib Copyright Chris Palmer 2020
+// nop.head@gmail.com
+// hydraraptor.blogspot.com
+//
+// This file is part of NopSCADlib.
+//
+// NopSCADlib is free software: you can redistribute it and/or modify it under the terms of the
+// GNU General Public License as published by the Free Software Foundation, either version 3 of
+// the License, or (at your option) any later version.
+//
+// NopSCADlib is distributed in the hope that it will be useful, but WITHOUT ANY WARRANTY;
+// without even the implied warranty of MERCHANTABILITY or FITNESS FOR A PARTICULAR PURPOSE.
+// See the GNU General Public License for more details.
+//
+// You should have received a copy of the GNU General Public License along with NopSCADlib.
+// If not, see <https://www.gnu.org/licenses/>.
+//
+//! Printed pulleys are a remix of droftarts's (see <https://www.thingiverse.com/droftarts/designs>) Parametric Pulleys
+//! on Thingiverse (see <https://www.thingiverse.com/thing:16627>) and are licensed under the
+//! Creative Commons - Attribution - Share Alike license (see <https://creativecommons.org/licenses/by-sa/3.0/>)
+//
+
+include <NopSCADlib/core.scad>
+include <NopSCADlib/vitamins/pulleys.scad>
+
+printed_pulley_GT2_profile = [[0.747183,-0.5],[0.747183,0],[0.647876,0.037218],[0.598311,0.130528],[0.578556,0.238423],[0.547158,0.343077],[0.504649,0.443762],[0.451556,0.53975],[0.358229,0.636924],[0.2484,0.707276],[0.127259,0.750044],[0,0.76447],[-0.127259,0.750044],[-0.2484,0.707276],[-0.358229,0.636924],[-0.451556,0.53975],[-0.504797,0.443762],[-0.547291,0.343077],[-0.578605,0.238423],[-0.598311,0.130528],[-0.648009,0.037218],[-0.747183,0],[-0.747183,-0.5]];
+
+function printed_pulley_inverted(type) = pulley_hub_dia(type) < pulley_flange_dia(type); //! Need to print upside down to prevent overhang
+
+function printed_pulley_od(tooth_count, tooth_pitch, pitch_line_offset)
+    = tooth_count * tooth_pitch / PI - 2 * pitch_line_offset;
+
+module printed_pulley_teeth_from_profile(tooth_count, tooth_depth, tooth_width, tooth_profile) {
+    pulley_od = printed_pulley_od(tooth_count, 2, 0.254);
+
+    difference() {
+        rotate (90 / tooth_count)
+            circle(r = pulley_od / 2, $fn = tooth_count * 4);
+        tooth_distance_from_centre = sqrt(pulley_od * pulley_od - (tooth_width + 0.2) * (tooth_width + 0.2)) / 2;
+        for(i = [1 : tooth_count])
+            rotate(i * 360 / tooth_count)
+                translate([0, -tooth_distance_from_centre])
+                    scale([(tooth_width + 0.2) / tooth_width, 1])
+                        polygon(tooth_profile);
+    }
+}
+
+module printed_pulley_GT2_teeth(type) {
+    tooth_count = pulley_teeth(type);
+    if (tooth_count == 0)
+        circle(r = pulley_od(type) / 2);
+    else
+        printed_pulley_teeth_from_profile(tooth_count, 0.764, 1.494, printed_pulley_GT2_profile);
+}
+
+
+module printed_pulley_teeth(type) { //! Draw the pulley's teeth
+    tooth_count = pulley_teeth(type);
+    tw = pulley_od(type) * PI / (tooth_count * 2);
+    ir = pulley_ir(type);
+    or = pulley_od(type) / 2;
+
+    T_angle = 40;
+    GT_r = 0.555;
+    for (i = [0 : 1 : tooth_count - 1])
+        rotate(i * 360 / tooth_count)
+            if (pulley_type(type)[0] == "G")
+                translate([0, ir + GT_r])
+                    hull() {
+                        circle(GT_r);
+                        translate([0, GT_r])
+                            square(2 * GT_r, center = true);
+                    }
+            else
+                translate([0, (ir + or) / 2])
+                    hull() {
+                        for(side = [-1, 1])
+                            translate([side * tw / 2, 0])
+                                rotate(-side * T_angle / 2)
+                                    square([eps, (or - ir)], center = true);
+
+                        translate([0, 1])
+                            square([tw, eps], center = true);
+                    }
+}
+
+module printed_pulley(type) { //! Draw a printable pulley
+    ft = pulley_flange_thickness(type);
+    hl = pulley_hub_length(type);
+    w = pulley_width(type);
+    r1 = pulley_bore(type) / 2;
+    or = pulley_od(type) / 2;
+    screw_z = pulley_screw_z(type);
+
+    stl(str("printed_pulley_", type[0]));
+
+    module core() {
+        translate_z(pulley_hub_length(type) + ft)
+            linear_extrude(w + 1) let($fa  = 1, $fs = 0.1)
+                if ("GT2" == str(pulley_type(type)[0], pulley_type(type)[1], pulley_type(type)[2]))
+                    difference() {
+                        printed_pulley_GT2_teeth(type);
+                        circle(d = pulley_bore(type));
+                    }
+                else
+                    difference() {
+                        circle(or);
+                        printed_pulley_teeth(type);
+                        circle(d = pulley_bore(type));
+                    }
+    }
+
+    module screw_holes() {
+        if(pulley_screws(type))
+            translate_z(screw_z)
+                for(i = [0 : pulley_screws(type) - 1])
+                    rotate([-90, 180, i * -90])
+                        if(show_supports())
+                            teardrop(r = screw_pilot_hole(pulley_screw(type)), h = pulley_flange_dia(type) / 2 + 1, center = false);
+                        else
+                            cylinder(r = screw_radius(pulley_screw(type)), h = pulley_flange_dia(type) / 2 + 1);
+    }
+
+    module hub()
+        linear_extrude(hl)
+            difference() {
+                circle(d= pulley_hub_dia(type));
+                circle(d = pulley_bore(type));
+            }
+
+    translate_z(printed_pulley_inverted(type) ? - hl : 0) {
+        // hub
+        if(hl)
+            translate_z(printed_pulley_inverted(type) ? hl + w + 2 * ft : 0)
+                if(screw_z && screw_z < hl)
+                    render()
+                        difference() {
+                            hub();
+
+                            screw_holes();
+                        }
+                else
+                    hub();
+
+        // bottom flange
+        translate_z(hl)
+            linear_extrude(ft)
+                difference() {
+                    circle(d = pulley_flange_dia(type));
+                    circle(d = pulley_bore(type));
+                }
+
+        // top flange
+        translate_z(hl + ft + w) {
+            // inner part, supported by core
+            linear_extrude(ft)
+                difference() {
+                    circle(r = or);
+                    circle(d = pulley_bore(type));
+                }
+            // outer part at 45 degrees for printing
+            rotate_extrude()
+                translate([or - eps, ft])
+                    vflip()
+                        right_triangle(ft, ft);
+        }
+
+        if(screw_z && screw_z > hl)
+            render()
+                difference() { // T5 pulleys have screws through the teeth
+                    core();
+
+                    translate_z(printed_pulley_inverted(type) ? pulley_height(type) + hl - 2 * screw_z : 0)
+                        screw_holes();
+                }
+            else
+                core();
+    }
+}
+
+module printed_pulley_assembly(type, colour = pp1_colour) //! Draw a printed pulley with its grub screws in place
+assembly(str("printed_pulley_", type[0])) {
+    translate_z(pulley_offset(type)) {
+        stl_colour(colour)
+            if(printed_pulley_inverted(type))
+                translate_z(pulley_height(type))
+                    hflip()
+                        printed_pulley(type);
+            else
+                printed_pulley(type);
+
+        if(pulley_screws(type))
+            translate_z(pulley_screw_z(type))
+                for(i = [0 : pulley_screws(type) - 1])
+                    rotate([-90, 0, i * -90])
+                        translate_z(pulley_bore(type) / 2 + pulley_screw_length(type))
+                            screw(pulley_screw(type), pulley_screw_length(type));
+    }
+}

readme.md

@@ -37,12 +37,12 @@ See [usage](docs/usage.md) for requirements, installation instructions and a usa
 <tr><td> <a href = "#Extrusions">Extrusions</a> </td><td> <a href = "#Opengrab">Opengrab</a> </td><td> <a href = "#Stepper_motors">Stepper_motors</a> </td><td> <a href = "#PSU_shroud">PSU_shroud</a> </td><td> <a href = "#Rounded_right_triangle">Rounded_right_triangle</a> </td><td></td></tr>
 <tr><td> <a href = "#Fans">Fans</a> </td><td> <a href = "#PCB">PCB</a> </td><td> <a href = "#Swiss_clips">Swiss_clips</a> </td><td> <a href = "#Press_fit">Press_fit</a> </td><td> <a href = "#Sector">Sector</a> </td><td></td></tr>
 <tr><td> <a href = "#Fuseholder">Fuseholder</a> </td><td> <a href = "#PCBs">PCBs</a> </td><td> <a href = "#Toggles">Toggles</a> </td><td> <a href = "#Printed_box">Printed_box</a> </td><td> <a href = "#Sweep">Sweep</a> </td><td></td></tr>
-<tr><td> <a href = "#Geared_steppers">Geared_steppers</a> </td><td> <a href = "#PSUs">PSUs</a> </td><td> <a href = "#Transformers">Transformers</a> </td><td> <a href = "#Ribbon_clamp">Ribbon_clamp</a> </td><td> <a href = "#Thread">Thread</a> </td><td></td></tr>
-<tr><td> <a href = "#Green_terminals">Green_terminals</a> </td><td> <a href = "#Panel_meters">Panel_meters</a> </td><td> <a href = "#Tubings">Tubings</a> </td><td> <a href = "#SSR_shroud">SSR_shroud</a> </td><td> <a href = "#Tube">Tube</a> </td><td></td></tr>
-<tr><td> <a href = "#Hot_ends">Hot_ends</a> </td><td> <a href = "#Pillars">Pillars</a> </td><td> <a href = "#Variacs">Variacs</a> </td><td> <a href = "#Screw_knob">Screw_knob</a> </td><td></td><td></td></tr>
-<tr><td> <a href = "#Hygrometer">Hygrometer</a> </td><td> <a href = "#Pin_headers">Pin_headers</a> </td><td> <a href = "#Veroboard">Veroboard</a> </td><td> <a href = "#Socket_box">Socket_box</a> </td><td></td><td></td></tr>
-<tr><td> <a href = "#IECs">IECs</a> </td><td> <a href = "#Pulleys">Pulleys</a> </td><td> <a href = "#Washers">Washers</a> </td><td> <a href = "#Strap_handle">Strap_handle</a> </td><td></td><td></td></tr>
-<tr><td> <a href = "#Inserts">Inserts</a> </td><td></td><td> <a href = "#Wire">Wire</a> </td><td></td><td></td><td></td></tr>
+<tr><td> <a href = "#Geared_steppers">Geared_steppers</a> </td><td> <a href = "#PSUs">PSUs</a> </td><td> <a href = "#Transformers">Transformers</a> </td><td> <a href = "#Printed_pulleys">Printed_pulleys</a> </td><td> <a href = "#Thread">Thread</a> </td><td></td></tr>
+<tr><td> <a href = "#Green_terminals">Green_terminals</a> </td><td> <a href = "#Panel_meters">Panel_meters</a> </td><td> <a href = "#Tubings">Tubings</a> </td><td> <a href = "#Ribbon_clamp">Ribbon_clamp</a> </td><td> <a href = "#Tube">Tube</a> </td><td></td></tr>
+<tr><td> <a href = "#Hot_ends">Hot_ends</a> </td><td> <a href = "#Pillars">Pillars</a> </td><td> <a href = "#Variacs">Variacs</a> </td><td> <a href = "#SSR_shroud">SSR_shroud</a> </td><td></td><td></td></tr>
+<tr><td> <a href = "#Hygrometer">Hygrometer</a> </td><td> <a href = "#Pin_headers">Pin_headers</a> </td><td> <a href = "#Veroboard">Veroboard</a> </td><td> <a href = "#Screw_knob">Screw_knob</a> </td><td></td><td></td></tr>
+<tr><td> <a href = "#IECs">IECs</a> </td><td> <a href = "#Pulleys">Pulleys</a> </td><td> <a href = "#Washers">Washers</a> </td><td> <a href = "#Socket_box">Socket_box</a> </td><td></td><td></td></tr>
+<tr><td> <a href = "#Inserts">Inserts</a> </td><td></td><td> <a href = "#Wire">Wire</a> </td><td> <a href = "#Strap_handle">Strap_handle</a> </td><td></td><td></td></tr>
 <tr><td></td><td></td><td> <a href = "#Zipties">Zipties</a> </td><td></td><td></td><td></td></tr>
 </table>
 
@@ -313,7 +313,7 @@ Models of radial blowers.
 |   4 | `screw(M2_cap_screw, 8)` |  Screw M2 cap x  8mm |
 |   3 | `screw(M3_cap_screw, 20)` |  Screw M3 cap x 20mm |
 |   2 | `screw(M4_cap_screw, 25)` |  Screw M4 cap x 25mm |
-|   1 | `blower(BL40x10)` |  Square radial 4010 |
+|   1 | `blower(BL40x10)` |  Square radial fan 4010 |
 |   4 | `washer(M2_washer)` |  Washer  M2 x 5mm x 0.3mm |
 |   3 | `washer(M3_washer)` |  Washer  M3 x 7mm x 0.5mm |
 |   2 | `washer(M4_washer)` |  Washer  M4 x 9mm x 0.8mm |
@@ -1048,10 +1048,12 @@ Parametric green terminal blocks
 ### Vitamins
 | Qty | Module call | BOM entry |
 | ---:|:--- |:---|
-|   1 | `green_terminal(gt_6p35, 2)` |  Terminal block 2 way 0.25" |
-|   1 | `green_terminal(gt_5p08, 3)` |  Terminal block 3 way 0.2" |
-|   1 | `green_terminal(gt_3p5, 4)` |  Terminal block 4 way 3.5mm |
-|   1 | `green_terminal(gt_2p54, 5)` |  Terminal block 5 way 0.1" |
+|   1 | `green_terminal(gt_5x17, 2)` |  Terminal block 2 way 5mm |
+|   1 | `green_terminal(gt_5x11, 3)` |  Terminal block 3 way 5mm |
+|   1 | `green_terminal(gt_6p35, 4)` |  Terminal block 4 way 0.25" |
+|   1 | `green_terminal(gt_5p08, 5)` |  Terminal block 5 way 0.2" |
+|   1 | `green_terminal(gt_3p5, 6)` |  Terminal block 6 way 3.5mm |
+|   1 | `green_terminal(gt_2p54, 7)` |  Terminal block 7 way 0.1" |
 
 
 <a href="#top">Top</a>
@@ -1102,17 +1104,17 @@ Needs updating as mostly obsolete versions.
 ### Vitamins
 | Qty | Module call | BOM entry |
 | ---:|:--- |:---|
-|   2 | `tubing(HSHRNK16)` |  Heatshrink sleeving ID 1.6mm x 15mm |
+|   2 | `tubing(HSHRNK16)` |  Heatshrink sleeving ID 1.6mm x 15mm - not shown |
 |   4 | `tubing(HSHRNK64, 60)` |  Heatshrink sleeving ID 6.4mm x 60mm |
 |   1 | `e3d_hot_end(E3Dv5, 3)` |  Hot end E3D V5 direct 3mm |
 |   1 | `e3d_hot_end(E3Dv6, 3)` |  Hot end E3D V6 direct 3mm |
 |   1 | `e3d_hot_end(E3D_clone, 3)` |  Hot end E3D clone aliexpress 3mm |
 |   1 | `jhead_hot_end(JHeadMk5, 3)` |  Hot end JHead MK5 3mm |
-|   2 | `tubing(PTFE07, 62)` |  PTFE sleeving OD 1.2mm ID 0.71mm x 62mm |
-|   2 | `tubing(PTFE20, 45)` |  PTFE sleeving OD 2.6mm ID 2mm x 45mm |
-|   1 | `resistor(RIE1212UB5C5R6)` |  Resistor UB5C 5R6F 5R6 3W vitreous enamel |
+|   2 | `tubing(PTFE07, 62)` |  PTFE sleeving OD 1.2mm ID 0.71mm x 62mm - not shown |
+|   2 | `tubing(PTFE20, 45)` |  PTFE sleeving OD 2.6mm ID 2mm x 45mm - not shown |
+|   1 | `resistor(RIE1212UB5C5R6)` |  Resistor UB5C 5R6F 5R6 3W vitreous enamel - not shown |
 |   1 |  |  Tape self amalgamating silicone 110mm x 25mm |
-|   1 | `resistor(Epcos)` |  Thermistor Epcos B57560G104F 100K 1% |
+|   1 | `resistor(Epcos)` |  Thermistor Epcos B57560G104F 100K 1% - not shown |
 |   2 |  |  Wire Red PTFE 16/0.2mm strands, length 170mm |
 |   4 | `ziptie(small_ziptie, 8)` |  Ziptie 2.5mm x 100mm min length |
 
@@ -2308,6 +2310,7 @@ PCBs and perfboard with optional components. The shape can be a rectangle with o
 |   1 | `pcb(DuetE)` |  Duet 2 Ethernet electronics |
 |   1 | `pcb(Duex2)` |  Duex2 expansion board |
 |   1 | `pcb(Duex5)` |  Duex5 expansion board |
+|   1 | `pcb(ESP-01)` |  ESP-01 |
 |   1 | `pcb(EnviroPlus)` |  Enviro+ |
 |   1 | `pcb(ExtruderPCB)` |  Extruder connection PCB |
 |   1 | `pcb(Keyes5p1)` |  Keyes5.1 Arduino Uno expansion board |
@@ -2337,8 +2340,8 @@ PCBs and perfboard with optional components. The shape can be a rectangle with o
 |   2 | `screw(M2p5_cap_screw, 20)` |  Screw M2.5 cap x 20mm |
 |   8 | `screw(M2p5_cap_screw, 25)` |  Screw M2.5 cap x 25mm |
 |   8 | `screw(M2p5_cap_screw, 30)` |  Screw M2.5 cap x 30mm |
-|   4 | `screw(M2p5_pan_screw, 20)` |  Screw M2.5 pan x 20mm |
 |  12 | `screw(M2p5_pan_screw, 25)` |  Screw M2.5 pan x 25mm |
+|   4 | `screw(M2p5_pan_screw, 30)` |  Screw M2.5 pan x 30mm |
 |   4 | `screw(M3_cap_screw, 16)` |  Screw M3 cap x 16mm |
 |   8 | `screw(M3_cap_screw, 30)` |  Screw M3 cap x 30mm |
 |  12 | `screw(M4_cap_screw, 35)` |  Screw M4 cap x 35mm |
@@ -2359,21 +2362,21 @@ PCBs and perfboard with optional components. The shape can be a rectangle with o
 |   4 | pcb_spacer2070.stl |
 |   4 | pcb_spacer2080.stl |
 |   4 | pcb_spacer2090.stl |
-|   4 | pcb_spacer25110.stl |
 |   4 | pcb_spacer25120.stl |
 |   4 | pcb_spacer25130.stl |
-|   4 | pcb_spacer25140_2.stl |
+|   4 | pcb_spacer25140.stl |
 |   4 | pcb_spacer25150_2.stl |
 |   4 | pcb_spacer25160_2.stl |
-|   4 | pcb_spacer25190.stl |
+|   4 | pcb_spacer25170_2.stl |
 |   4 | pcb_spacer25200.stl |
-|   2 | pcb_spacer2580.stl |
-|   4 | pcb_spacer30170.stl |
+|   4 | pcb_spacer25210.stl |
+|   2 | pcb_spacer2590.stl |
 |   4 | pcb_spacer30180.stl |
+|   4 | pcb_spacer30190.stl |
 |   4 | pcb_spacer3050.stl |
-|   4 | pcb_spacer40210.stl |
 |   4 | pcb_spacer40220.stl |
 |   4 | pcb_spacer40230.stl |
+|   4 | pcb_spacer40240.stl |
 
 
 <a href="#top">Top</a>
@@ -2658,6 +2661,8 @@ Linear rails with carriages.
 | `rail_carriage(type)` | Carriage type |
 | `rail_end(type)` | Minimum distance screw can be from the end |
 | `rail_end_screw(type)` | Screw used for ends only (Countersink used for better location) |
+| `rail_groove_offset(type)` | Offset of centre of groove from top of rail |
+| `rail_groove_width(type)` | Groove width |
 | `rail_height(type)` | Height of rail section |
 | `rail_hole(type)` | Screw hole diameter |
 | `rail_pitch(type)` | Distance between screws |
@@ -2678,7 +2683,7 @@ Linear rails with carriages.
 |:--- |:--- |
 | `carriage(type, rail, end_colour = grey(20)` | Draw the specified carriage |
 | `carriage_hole_positions(type)` | Position children over screw holes |
-| `rail(type, length)` | Draw the specified rail |
+| `rail(type, length, colour = grey(90)` | Draw the specified rail |
 | `rail_assembly(type, length, pos, carriage_end_colour = grey(20)` | Rail and carriage assembly |
 | `rail_hole_positions(type, length, first = 0, screws = 100, both_ends = true)` | Position children over screw holes |
 | `rail_screws(type, length, thickness, screws = 100, index_screws = undef)` | Place screws in the rail |
@@ -4559,7 +4564,7 @@ to the assembly, for example to add inserts.
 ### Modules
 | Module | Description |
 |:--- |:--- |
-| `drag_chain_assembly(type, pos = 0)` | Drag chain assembly |
+| `drag_chain_assembly(type, pos = 0, render = false)` | Drag chain assembly |
 | `drag_chain_link(type, start = false, end = false, check_kids = true)` | One link of the chain, special case for start and end |
 | `drag_chain_screw_positions(type, end)` | Place children at the screw positions, end = 0 for the start, 1 for the end |
 | `screw_lug(screw, h = 0)` | Create a D shaped lug for a screw |
@@ -5039,6 +5044,73 @@ It can also have printed feet on the base with the screws doubling up to hold th
 |   1 | box2_assembly |
 
 
+<a href="#top">Top</a>
+
+---
+<a name="Printed_pulleys"></a>
+## Printed_pulleys
+Printed pulleys are a remix of droftarts's (see <https://www.thingiverse.com/droftarts/designs>) Parametric Pulleys
+on Thingiverse (see <https://www.thingiverse.com/thing:16627>) and are licensed under the
+Creative Commons - Attribution - Share Alike license (see <https://creativecommons.org/licenses/by-sa/3.0/>)
+
+[printed/printed_pulleys.scad](printed/printed_pulleys.scad) Implementation.
+
+[tests/printed_pulleys.scad](tests/printed_pulleys.scad) Code for this example.
+
+### Functions
+| Function | Description |
+|:--- |:--- |
+| `printed_pulley_inverted(type)` | Need to print upside down to prevent overhang |
+
+### Modules
+| Module | Description |
+|:--- |:--- |
+| `printed_pulley(type)` | Draw a printable pulley |
+| `printed_pulley_assembly(type, colour = pp1_colour)` | Draw a printed pulley with its grub screws in place |
+| `printed_pulley_teeth(type)` | Draw the pulley's teeth |
+
+![printed_pulleys](tests/png/printed_pulleys.png)
+
+### Vitamins
+| Qty | Module call | BOM entry |
+| ---:|:--- |:---|
+|   1 | `screw(M3_grub_screw, 3)` |  Screw M3 grub x  3mm |
+|   2 | `screw(M3_grub_screw, 4.5)` |  Screw M3 grub x  4.5mm |
+|   2 | `screw(M3_grub_screw, 4)` |  Screw M3 grub x  4mm |
+|   4 | `screw(M3_grub_screw, 6)` |  Screw M3 grub x  6mm |
+|   1 | `screw(M4_grub_screw, 6)` |  Screw M4 grub x  6mm |
+
+### Printed
+| Qty | Filename |
+| ---:|:--- |
+|   1 | printed_pulley_GT2x12_pulley.stl |
+|   1 | printed_pulley_GT2x16_plain_idler.stl |
+|   1 | printed_pulley_GT2x16_pulley.stl |
+|   1 | printed_pulley_GT2x16_toothed_idler.stl |
+|   1 | printed_pulley_GT2x16x7_plain_idler.stl |
+|   1 | printed_pulley_GT2x20_plain_idler.stl |
+|   1 | printed_pulley_GT2x20_toothed_idler.stl |
+|   1 | printed_pulley_GT2x20ob_pulley.stl |
+|   1 | printed_pulley_GT2x20um_pulley.stl |
+|   1 | printed_pulley_T2p5x16_pulley.stl |
+|   1 | printed_pulley_T5x10_pulley.stl |
+
+### Assemblies
+| Qty | Name |
+| ---:|:--- |
+|   1 | printed_pulley_GT2x12_pulley_assembly |
+|   1 | printed_pulley_GT2x16_plain_idler_assembly |
+|   1 | printed_pulley_GT2x16_pulley_assembly |
+|   1 | printed_pulley_GT2x16_toothed_idler_assembly |
+|   1 | printed_pulley_GT2x16x7_plain_idler_assembly |
+|   1 | printed_pulley_GT2x20_plain_idler_assembly |
+|   1 | printed_pulley_GT2x20_toothed_idler_assembly |
+|   1 | printed_pulley_GT2x20ob_pulley_assembly |
+|   1 | printed_pulley_GT2x20um_pulley_assembly |
+|   1 | printed_pulley_T2p5x16_pulley_assembly |
+|   1 | printed_pulley_T5x10_pulley_assembly |
+
+
 <a href="#top">Top</a>
 
 ---
@@ -6183,12 +6255,12 @@ do not intrude into the circle. See <https://hydraraptor.blogspot.com/2020/07/ho
 ### Modules
 | Module | Description |
 |:--- |:--- |
-| `semi_teardrop(h, r, d = undef, center = true, chamfer = 0, plus = false)` | A semi teardrop in the positive Y domain |
-| `teardrop(h, r, center = true, truncate = true, chamfer = 0, plus = false)` | For making horizontal holes that don't need support material, set `truncate = false` to make traditional RepRap teardrops that don't even need bridging |
-| `teardrop_chamfer(h, center, chamfer)` | Helper module for adding chamfer to a teardrop |
-| `teardrop_plus(h, r, center = true, truncate = true, chamfer = 0)` | Slightly elongated teardrop to allow for the 3D printing staircase effect |
-| `tearslot(h, r, w, center = true, chamfer = 0, plus = false)` | A horizontal slot that doesn't need support material |
-| `vertical_tearslot(h, r, l, center = true, chamfer = 0, plus = false)` | A vertical slot that doesn't need support material |
+| `semi_teardrop(h, r, d = undef, center = true, chamfer = 0, chamfer_both_ends = true, plus = false)` | A semi teardrop in the positive Y domain |
+| `teardrop(h, r, center = true, truncate = true, chamfer = 0, chamfer_both_ends = true, plus = false)` | For making horizontal holes that don't need support material, set `truncate = false` to make traditional RepRap teardrops that don't even need bridging |
+| `teardrop_chamfer(h, center, chamfer, chamfer_both_ends)` | Helper module for adding chamfer to a teardrop |
+| `teardrop_plus(h, r, center = true, truncate = true, chamfer = 0, chamfer_both_ends = true)` | Slightly elongated teardrop to allow for the 3D printing staircase effect |
+| `tearslot(h, r, w, center = true, chamfer = 0, chamfer_both_ends = true, plus = false)` | A horizontal slot that doesn't need support material |
+| `vertical_tearslot(h, r, l, center = true, chamfer = 0, chamfer_both_ends = true, plus = false)` | A vertical slot that doesn't need support material |
 
 ![teardrops](tests/png/teardrops.png)
 

scripts/tests.py

@@ -56,7 +56,7 @@ def compare_images(a, b, c):
     with open(log_name, 'w') as output:
         do_cmd(("magick compare -metric AE -fuzz %d%% %s %s %s" % (fuzz, a, b, c)).split(), output = output)
     with open(log_name, 'r') as f:
-        pixels = int(f.read().strip())
+        pixels = int(float(f.read().strip()))
     os.remove(log_name)
     return pixels
 

tests/printed_pulleys.scad

@@ -0,0 +1,45 @@
+//
+// NopSCADlib Copyright Chris Palmer 2020
+// nop.head@gmail.com
+// hydraraptor.blogspot.com
+//
+// This file is part of NopSCADlib.
+//
+// NopSCADlib is free software: you can redistribute it and/or modify it under the terms of the
+// GNU General Public License as published by the Free Software Foundation, either version 3 of
+// the License, or (at your option) any later version.
+//
+// NopSCADlib is distributed in the hope that it will be useful, but WITHOUT ANY WARRANTY;
+// without even the implied warranty of MERCHANTABILITY or FITNESS FOR A PARTICULAR PURPOSE.
+// See the GNU General Public License for more details.
+//
+// You should have received a copy of the GNU General Public License along with NopSCADlib.
+// If not, see <https://www.gnu.org/licenses/>.
+//
+
+include <../core.scad>
+include <../vitamins/pulleys.scad>
+include <../printed/printed_pulleys.scad>
+use <../utils/layout.scad>
+
+
+module printed_pulley_test(show_metal = false) {
+    layout([for (p = pulleys) pulley_flange_dia(p)]) let(p = pulleys[$i]) {
+        rotate(-145)
+            if($preview)
+                printed_pulley_assembly(p);
+            else
+                printed_pulley(p);
+
+        if(show_metal)
+            not_on_bom()
+                translate([0, 20])
+                    rotate(-145)
+                        pulley_assembly(p);
+    }
+}
+
+if($preview)
+    printed_pulley_test(true);
+else
+    printed_pulley_test();

tests/pulleys.scad

@@ -23,7 +23,7 @@ include <../vitamins/pulleys.scad>
 
 module pulleys()
     layout([for(p = pulleys) pulley_flange_dia(p)])
-        rotate(-45)
+        rotate(-145)
             pulley_assembly(pulleys[$i]);
 
 if($preview)

utils/core/teardrops.scad

@@ -24,7 +24,7 @@
 //! Using teardrop_plus() or setting the plus option on other modules will elongate the teardrop vertically by the layer height, so when sliced the staircase tips
 //! do not intrude into the circle. See <https://hydraraptor.blogspot.com/2020/07/horiholes-2.html>
 //
-module teardrop(h, r, center = true, truncate = true, chamfer = 0, plus = false) { //! For making horizontal holes that don't need support material, set `truncate = false` to make traditional RepRap teardrops that don't even need bridging
+module teardrop(h, r, center = true, truncate = true, chamfer = 0, chamfer_both_ends = true, plus = false) { //! For making horizontal holes that don't need support material, set `truncate = false` to make traditional RepRap teardrops that don't even need bridging
     module teardrop_2d(r, truncate) {
         er = layer_height / 2 - eps;    // Extrustion edge radius
         R = plus ? r + er : r;          // Corrected radius
@@ -52,7 +52,7 @@ module teardrop(h, r, center = true, truncate = true, chamfer = 0, plus = false)
         extrude_if(h, center)
             teardrop_2d(r, truncate);
 
-    teardrop_chamfer(h, center, chamfer) {
+    teardrop_chamfer(h, center, chamfer, chamfer_both_ends) {
         linear_extrude(eps, center = true)
             teardrop_2d(r + chamfer / 2, truncate);
 
@@ -62,7 +62,7 @@ module teardrop(h, r, center = true, truncate = true, chamfer = 0, plus = false)
     }
 }
 
-module semi_teardrop(h, r, d = undef, center = true, chamfer = 0, plus = false) { //! A semi teardrop in the positive Y domain
+module semi_teardrop(h, r, d = undef, center = true, chamfer = 0, chamfer_both_ends = true, plus = false) { //! A semi teardrop in the positive Y domain
     module semi_teardrop_2d(r, d)
         intersection() {
             R = is_undef(d) ? r : d / 2;
@@ -77,7 +77,7 @@ module semi_teardrop(h, r, d = undef, center = true, chamfer = 0, plus = false)
         extrude_if(h, center)
             semi_teardrop_2d(r, d);
 
-    teardrop_chamfer(h, center, chamfer) {
+    teardrop_chamfer(h, center, chamfer, chamfer_both_ends) {
         linear_extrude(eps, center = true)
             semi_teardrop_2d(r + chamfer / 2, d);
 
@@ -87,10 +87,10 @@ module semi_teardrop(h, r, d = undef, center = true, chamfer = 0, plus = false)
     }
 }
 
-module teardrop_plus(h, r, center = true, truncate = true, chamfer = 0) //! Slightly elongated teardrop to allow for the 3D printing staircase effect
-    teardrop(h, r, center, truncate, chamfer, plus = true);
+module teardrop_plus(h, r, center = true, truncate = true, chamfer = 0, chamfer_both_ends = true) //! Slightly elongated teardrop to allow for the 3D printing staircase effect
+    teardrop(h, r, center, truncate, chamfer, chamfer_both_ends, plus = true);
 
-module tearslot(h, r, w, center = true, chamfer = 0, plus = false) { //! A horizontal slot that doesn't need support material
+module tearslot(h, r, w, center = true, chamfer = 0, chamfer_both_ends = true, plus = false) { //! A horizontal slot that doesn't need support material
     module tearslot_2d(r, w)
         hull()
             for(x = [-1, 1])
@@ -99,7 +99,7 @@ module tearslot(h, r, w, center = true, chamfer = 0, plus = false) { //! A horiz
     extrude_if(h, center)
         tearslot_2d(r, w);
 
-    teardrop_chamfer(h, center, chamfer) {
+    teardrop_chamfer(h, center, chamfer, chamfer_both_ends) {
         linear_extrude(eps, center = true)
             tearslot_2d(r + chamfer / 2, w);
 
@@ -109,7 +109,7 @@ module tearslot(h, r, w, center = true, chamfer = 0, plus = false) { //! A horiz
     }
 }
 
-module vertical_tearslot(h, r, l, center = true, chamfer = 0, plus = false) { //! A vertical slot that doesn't need support material
+module vertical_tearslot(h, r, l, center = true, chamfer = 0, chamfer_both_ends = true, plus = false) { //! A vertical slot that doesn't need support material
     module vertical_tearslot_2d(r, l)
         hull()
             for(y = [-1, 1])
@@ -119,7 +119,7 @@ module vertical_tearslot(h, r, l, center = true, chamfer = 0, plus = false) { //
     extrude_if(h, center)
         vertical_tearslot_2d(r, l);
 
-    teardrop_chamfer(h, center, chamfer) {
+    teardrop_chamfer(h, center, chamfer, chamfer_both_ends) {
         linear_extrude(eps, center = true)
             vertical_tearslot_2d(r + chamfer / 2, l);
 
@@ -129,10 +129,10 @@ module vertical_tearslot(h, r, l, center = true, chamfer = 0, plus = false) { //
     }
 }
 
-module teardrop_chamfer(h, center, chamfer) { //! Helper module for adding chamfer to a teardrop
+module teardrop_chamfer(h, center, chamfer, chamfer_both_ends) { //! Helper module for adding chamfer to a teardrop
     if(h && chamfer)
         translate_z(center ? 0 : h / 2)
-            for(m = [0, 1])
+            for(m = chamfer_both_ends ? [0, 1] : [1])
                 mirror([0, 0, m])
                     translate_z((h - eps ) / 2)
                         hull()

vitamins/blowers.scad

@@ -24,7 +24,7 @@
 //                                                   h                                                   h    s                                         t         t
 RB5015 = ["RB5015", "Blower Runda RB5015",           51.3, 51, 15, 31.5, M4_cap_screw, 26, [27.3, 25.4], 4.5, [[4.3, 45.4], [47.3,7.4]],     20,   14,  1.5, 1.3, 1.2, 15];
 PE4020 = ["PE4020", "Blower Pengda Technology 4020", 40,   40, 20, 27.5, M3_cap_screw, 22, [21.5, 20  ], 3.2, [[37,3],[3,37],[37,37]],       29.3, 17,  1.7, 1.2, 1.3, 13];
-BL40x10 =["BL40x10","Square radial 4010",            40,   40,9.5, 27,   M2_cap_screw, 16, [24,   20  ], 2.4, [[2,2],[38,2],[2,38],[38,38]], 30  , 9.5, 1.5, 1.5, 1.1, 1.5];
+BL40x10 =["BL40x10","Square radial fan 4010",        40,   40,9.5, 27,   M2_cap_screw, 16, [24,   20  ], 2.4, [[2,2],[38,2],[2,38],[38,38]], 30  , 9.5, 1.5, 1.5, 1.1, 1.5];
 
 blowers = [BL40x10, PE4020, RB5015];
 

vitamins/displays.scad

@@ -73,39 +73,54 @@ SSD1963_4p3 = ["SSD1963_4p3", "LCD display SSD1963 4.3\"", 105.5, 67.2, 3.4, SSD
         [[0, -34.5], [12, -31.5]],
         ];
 
+
+/* Dimensions taken from:
+https://github.com/bigtreetech/BIGTREETECH-TFT35-V3.0/blob/master/Hardware/TFT35%20V3.0-SIZE-TOP.pdf
+and
+https://github.com/bigtreetech/BIGTREETECH-TFT35-V3.0/blob/master/Hardware/TFT35%20V3.0-SIZE-BOT.pdf
+*/
+
 BigTreeTech_TFT35v3_0_PCB = ["", "",
-    110, 55.77, 1.6, 0, 3, 0, "green",  false,
-    [ [-3.12, 3.17], [-3.12, -3.17], [3.12, -3.17], [3.12, 3.17] ],
-    [
-        [  10, 7.5,    0, "-button_6mm" ],
-        [   9,  43,    0, "-buzzer", 5, 9 ],
-        [   9,  27,    0, "-potentiometer" ],
-        [ 102,28.82,   0, "uSD", [26.5, 16, 3] ],
-        [16.5, 5.9,    0, "2p54boxhdr", 5, 2 ],
-        [36.5, 5.9,    0, "2p54boxhdr", 5, 2 ],
-        [56.5, 5.9,    0, "2p54boxhdr", 5, 2 ],
-        [82.5,   4,    0, "jst_xh", 5 ],
-        [26.5, 52.8, 180, "jst_xh", 2 ],
-        [39.5, 52.8, 180, "jst_xh", 3 ],
-        [52.5, 52.8, 180, "jst_xh", 3 ],
-        [65.5, 52.8, 180, "jst_xh", 3 ],
-        [78.5, 52.8, 180, "jst_xh", 3 ],
-        [94.5, 52.8, 180, "jst_xh", 5 ],
-        [   8,  43,  180, "usb_A" ],
-        [  97,   4,    0, "chip", 9, 3.5, 1, grey(20) ],
-        // ESP-8266
-        [  23,  28,   90, "2p54socket", 4, 2 ],
+    110, 55.77, 1.6, // size
+     0, // corner radius
+     3, // mounting hole diameter
+     0, // pad around mounting hole
+    "green", // color
+    false, // true if parts should be separate BOM items
+    [ // hole positions
+         [-3.12, 3.17], [-3.12, -3.17], [3.12, -3.17], [3.12, 3.17]
     ],
-    []
+    [ // components
+        [                 9, -( 8.46 + 17.45)/2,    0, "-buzzer", 5, 9 ],
+        [                 9, -(23.76 + 34.94)/2,    0, "-potentiometer" ],
+        [  (6.84 + 12.85)/2, -(45.73 + 51.73)/2,    0, "-button_6mm" ],
+        [               102,  (15.57 + 42.07)/2,    0, "uSD", [26.5, 16, 3] ],
+        [                 8, -( 6.76 + 18.76)/2,  180, "usb_A" ],
+        [                23,  (23.32 + 33.64)/2,   90, "2p54socket", 4, 2 ], // ESP-8266
+
+        [ 16.5, 5.9,    0, "2p54boxhdr", 5, 2 ],
+        [ 36.5, 5.9,    0, "2p54boxhdr", 5, 2 ],
+        [ 56.5, 5.9,    0, "2p54boxhdr", 5, 2 ],
+        [ 82.5,   4,    0, "jst_xh", 5 ],
+        [ 26.5, 52.8, 180, "jst_xh", 2 ],
+        [ 39.5, 52.8, 180, "jst_xh", 3 ],
+        [ 52.5, 52.8, 180, "jst_xh", 3 ],
+        [ 65.5, 52.8, 180, "jst_xh", 3 ],
+        [ 78.5, 52.8, 180, "jst_xh", 3 ],
+        [ 94.5, 52.8, 180, "jst_xh", 5 ],
+        [ 97,    4,     0, "chip", 9, 3.5, 1, grey(20) ],
+    ],
+    [] // accessories
 ];
 
 BigTreeTech_TFT35v3_0 = ["BigTreeTech_TFT35v3_0", "BigTreeTech TFT35 v3.0",
-    84.5, 54.5, 4, BigTreeTech_TFT35v3_0_PCB,
-    [-6, 0, 0],                         // pcb offset
+    84.5, 54.5, 4,                      // size
+    BigTreeTech_TFT35v3_0_PCB,          // pcb
+    [7 - (110 - 84.5)/2, 0, 0],         // pcb offset from center
     [[-40, -26.5], [41.5, 26.5, 0.5]],  // aperture
-    [],                                 // touch screen
-    0,                                  // thread length
-    [],                                 // clearance need for the ts ribbon
+    [],                                 // touch screen position and size
+    0,                                  // length that studs protrude from the PCB holes
+    [],                                 // keep out region for ribbon cable
 ];
 
 

vitamins/green_terminals.scad

@@ -31,7 +31,9 @@ gt_2p54 = ["gt_2p54", 2.54,  6.6,   10, 3,    6, 0.4,  6.4, 1,    1,    0.2, 2,
 gt_3p5  = ["gt_3p5",  3.5,   7.3,  8.5, 4,    5, 0.4,  4,   0,    1.35, 0.4, 1.8, 2,   2,   0,   0,    0];
 gt_5p08 = ["gt_5p08", 5.08,  7.9,   10, 5.0,  7, 0.0,  6.8, 1.45, 1.95, 0.5, 4.0, 5.4, 0.5, 0,   0,    0];
 gt_6p35 = ["gt_6p35", 6.35, 12.6, 17.4, 6.8, 12, 0.4, 11,   2,    2.7,  0.8, 3.4, 4.2, 2,   1.8, 1.1, 21.4];
+gt_5x11 = ["gt_5x11",    5,    8,   11, 5,    7, 0.4,  7,   1.5,  1.5,  1,   2.5, 6,   0,   0,   0,    0];
+gt_5x17 = ["gt_5x17",    5,   10,   17, 5,   11, 0.4,  9,   2,    1.5,  1,   3,   6,   0,   0,   0,    0];
 
-green_terminals = [gt_2p54, gt_3p5, gt_5p08, gt_6p35];
+green_terminals = [gt_2p54, gt_3p5, gt_5p08, gt_6p35, gt_5x11, gt_5x17];
 
 use <green_terminal.scad>

vitamins/jhead.scad

@@ -194,12 +194,14 @@ module jhead_hot_end_assembly(type, filament, naked = false) { //! Assembly with
             if(exploded())
                 heater_components();
             else
-                intersection() {
-                    heater_components();
+                if(naked)                       // hide the wires when not exploded
+                    intersection() {
+                        heater_components();
 
-                    if(naked)
-                        color("grey") cylinder(r = 12, h = 100, center = true);
-                    else
-                        cube(1, true);             // hide the wires when not exploded
-                }
+                        color("grey")
+                            cylinder(r = 12, h = 100, center = true);
+                    }
+                else
+                    hidden()                    // hidden by the tape
+                        heater_components();
 }

vitamins/pcbs.scad

@@ -414,8 +414,33 @@ RAMPSEndstop = ["RAMPSEndstop", "RAMPS Endstop Switch",
     ],
     []];
 
+ESP_01 = [
+    "ESP-01", "ESP-01",
+    24.8, 14.6, 1, // size
+    0, // corner radius
+    0, // mounting hole diameter
+    0, // pad around mounting hole
+    grey(25), // color
+    false, // true if parts should be separate BOM items
+    [], // hole positions
+    [ // components
+        [   2.8,   -7.25, 0, "-2p54header", 2, 4 ],
+        [ -14.55, -11.3,  0, "chip", 5.25, 5.25, 2.25, grey(15) ],
+        [ -14,     -5.2,  0, "chip", 4.5,  4.75, 1.1,  grey(15) ],
+        // antenna
+        for (y = [ 2.8  : 2.3 : 7.4  ]) [ -0.7, -y,  0, "block", 0.7, 1.75, 0.1,  gold ],
+        for (y = [ 4    : 2.3 : 10.6 ]) [ -4.3, -y,  0, "block", 0.7, 1.75, 0.1,  gold ],
+        for (y = [ 3.4  : 2.3 : 10.1 ]) [ -2.5, -y,  0, "block", 4.3, 0.7,  0.1,  gold ],
+        for (y = [ 4.55 : 2.3 : 11.2 ]) [ -2.5, -y,  0, "block", 4.3, 0.7,  0.1,  gold ],
 
-pcbs = [MP1584EN, TP4056, MT3608, RAMPSEndstop, ExtruderPCB, PI_IO, ZC_A0591, RPI0, EnviroPlus, ArduinoUno3, ArduinoLeonardo, Keyes5p1, PSU12V1A, WD2002SJ, RPI3, RPI4, DuetE, Duex2, Duex5];
+        [ -0.7, -10.85,  0, "block", 0.7,3.75,  0.1,  gold ],
+        [ -6.6,  -5.8,   0, "block", 0.7, 7.5,  0.1,  gold ],
+        [ -4.8,  -2.3,   0, "block", 8.8, 0.7,  0.1,  gold ],
+    ],
+    [] // accessories
+];
+
+pcbs = [MP1584EN, TP4056, ESP_01, MT3608, RAMPSEndstop, ExtruderPCB, PI_IO, ZC_A0591, RPI0, EnviroPlus, ArduinoUno3, ArduinoLeonardo, Keyes5p1, PSU12V1A, WD2002SJ, RPI3, RPI4, DuetE, Duex2, Duex5];
 
 perfboards = [PERF74x51, PERF70x50, PERF60x40, PERF70x30, PERF80x20];
 

vitamins/rail.scad

@@ -33,6 +33,9 @@ function rail_bore_depth(type) = type[7];   //! Counter bore depth
 function rail_screw(type)      = type[8];   //! Screw type
 function rail_carriage(type)   = type[9];   //! Carriage type
 function rail_end_screw(type)  = type[10];  //! Screw used for ends only (Countersink used for better location)
+function rail_groove_offset(type)=type[11]; //! Offset of centre of groove from top of rail
+function rail_groove_width(type)=type[12];  //! Groove width
+
 function rail_screw_height(type, screw) = rail_height(type) - rail_bore_depth(type) + screw_head_depth(screw, rail_hole(type)); //! Position screw taking into account countersink into counterbored hole
 function rail_travel(type, length) = length - carriage_length(rail_carriage(type)); //! How far the carriage can travel
 
@@ -134,43 +137,45 @@ module carriage(type, rail, end_colour = grey(20), wiper_colour = grey(20)) { //
             carriage_end(type, end_w, end_h, end_l);
 }
 
-module rail(type, length) { //! Draw the specified rail
+module rail(type, length, colour = grey(90), use_polycircles = false) { //! Draw the specified rail
     width = rail_width(type);
     height = rail_height(type);
 
     vitamin(str("rail(", type[0], ", ", length, "): Linear rail ", type[0], " x ", length, "mm"));
 
-    color(grey(90)) {
+    color(colour) {
+        rbr = rail_bore(type) / 2;
+        w = corrected_radius(rbr) * 2 + 2 * eps; // width of core big enough for the holes
         linear_extrude(height - rail_bore_depth(type)) difference() {
-            square([length, width], center = true);
+            square([length, w], center = true);
+
             rail_hole_positions(type, length)
-                 circle(d = rail_hole(type));
+                if (use_polycircles)
+                    poly_circle(rail_hole(type) / 2);
+                else
+                    circle(d = rail_hole(type));
         }
+        translate_z(rail_height(type) - rail_bore_depth(type))
+            linear_extrude(rail_bore_depth(type)) difference() {
+                square([length, w], center = true);
 
-        translate_z(rail_height(type) - rail_bore_depth(type)) {
-            h1 = rail_bore_depth(type) > 2 ? rail_bore_depth(type) / 3 : rail_bore_depth(type) / 2;
-            h0 = rail_bore_depth(type) > 2 ? (rail_bore_depth(type) - h1) / 2 : 0;
-            h2 = rail_bore_depth(type) - h1 - h0;
-
-            linear_extrude(h0) difference() {
-                square([length, width], center = true);
                 rail_hole_positions(type, length)
-                     circle(d = rail_bore(type));
+                    if (use_polycircles)
+                        poly_circle(rbr);
+                    else
+                        circle(rbr);
             }
-            translate_z(h0)
-                linear_extrude(h1) difference() {
-                    w1 = max(width - 2, rail_bore(type));
-                    square([length, w1], center = true);
-                    rail_hole_positions(type, length)
-                        circle(d = rail_bore(type));
-                }
-            translate_z(h0 + h1)
-                linear_extrude(h2) difference() {
-                    square([length, width], center = true);
-                    rail_hole_positions(type, length)
-                        circle(d = rail_bore(type));
-                }
-        }
+
+        go = height - rail_groove_offset(type);
+        gw = rail_groove_width(type);
+        gd = gw / 2;
+        sw = (width - w) / 2;
+        for (m = [0, 1])
+            mirror([0, m, 0])
+                translate([0, -width / 2])
+                    rotate([0, -90, 0])
+                        linear_extrude(length, center = true)
+                            polygon([ [0, 0], [0, sw], [height, sw], [height, 0], [go + gw/2, 0], [go, gd], [go - gw/2, 0] ]);
     }
 }
 

vitamins/rails.scad

@@ -32,14 +32,14 @@ SSR15_carriage = [ 40.3, 23.3, 34, 24, 4.5, 0,  26, M4_cap_screw ];
 // Rails
 //
 //
-//                Wr  Hr   E    P   D    d    h
-MGN5 = [ "MGN5",  5,  3.6, 5,   15, 3.6, 2.4, 0.8, M2_cs_cap_screw, MGN5_carriage, M2_cs_cap_screw ]; // Screw holes too small for M2 heads
-MGN7 = [ "MGN7",  7,  5,   5,   15, 4.3, 2.4, 2.6, M2_cap_screw,    MGN7_carriage, M2_cs_cap_screw ];
-MGN9 = [ "MGN9",  9,  6,   7.5, 20, 6.0, 3.5, 3.5, M3_cap_screw,    MGN9_carriage, M3_cs_cap_screw ];
-MGN12= [ "MGN12", 12, 8,   10,  25, 6.0, 3.5, 4.5, M3_cap_screw,   MGN12_carriage, M3_cs_cap_screw ];
-MGN12H=[ "MGN12H",12, 8,   10,  25, 6.0, 3.5, 4.5, M3_cap_screw,   MGN12H_carriage,M3_cs_cap_screw ];
-MGN15= [ "MGN15", 15, 10,  10,  40, 6.0, 3.5, 5.0, M3_cap_screw,   MGN15_carriage, M3_cs_cap_screw ];
-SSR15= [ "SSR15", 15, 12.5,10,  60, 7.5, 4.5, 5.3, M4_cap_screw,   SSR15_carriage, M4_cs_cap_screw ];
+//                Wr  Hr   E    P   D    d    h                                                      go    gw
+MGN5 = [ "MGN5",  5,  3.6, 5,   15, 3.6, 2.4, 0.8, M2_cs_cap_screw, MGN5_carriage, M2_cs_cap_screw,  1,    1 ]; // Screw holes too small for M2 heads
+MGN7 = [ "MGN7",  7,  5,   5,   15, 4.3, 2.4, 2.6, M2_cap_screw,    MGN7_carriage, M2_cs_cap_screw,  1.5,  1.5 ];
+MGN9 = [ "MGN9",  9,  6,   7.5, 20, 6.0, 3.5, 3.5, M3_cap_screw,    MGN9_carriage, M3_cs_cap_screw,  1.5,  1.5 ];
+MGN12= [ "MGN12", 12, 8,   10,  25, 6.0, 3.5, 4.5, M3_cap_screw,   MGN12_carriage, M3_cs_cap_screw,  2.25, 2.75 ];
+MGN12H=[ "MGN12H",12, 8,   10,  25, 6.0, 3.5, 4.5, M3_cap_screw,   MGN12H_carriage,M3_cs_cap_screw,  2.25, 2.75];
+MGN15= [ "MGN15", 15, 10,  10,  40, 6.0, 3.5, 5.0, M3_cap_screw,   MGN15_carriage, M3_cs_cap_screw,  2.5,  2.75 ];
+SSR15= [ "SSR15", 15, 12.5,10,  60, 7.5, 4.5, 5.3, M4_cap_screw,   SSR15_carriage, M4_cs_cap_screw,  2.5,  2.75 ];
 
 rails = [MGN5, MGN7, MGN9, MGN12, MGN12H, MGN15, SSR15];
 

vitamins/screw.scad

@@ -262,7 +262,7 @@ module screw_countersink(type, drilled = true) { //! Countersink shape
             if(drilled)
                 cylinder(h = head_height + eps, r1 = 0, r2 = head_rad + head_t);
             else
-                intersection() {
+                render() intersection() {
                     cylinder(h = head_height + eps, r1 = 0, r2 = head_rad + head_t);
 
                     cylinder(h = head_height + eps, r = head_rad + eps);