Nozzle cover and mold adjustments

- codpiece for the nozzle;
- shortened molds for single component silicone, namely
  Abro "The Gasket Maker" Red ("abro" flag in stuff.scad).

Signed-off-by: Ivan Kokshaysky <ink@rc.ru>

3 files changed, 50 insertions, 7 deletions

diff --git a/e3dv6.scad b/e3dv6.scad
index 902eb52..9b74f8a 100644
--- a/e3dv6.scad
+++ b/e3dv6.scad
@@ -1,99 +1,138 @@
 include <stuff.scad>;
 
 hb_w = 16;		// width (along X axis)
 hb_l = 20;		// length (along Y axis)
 hb_h = 11.5;		// height (guess!)
 hb_d = 6;		// heatbreak diameter
 n_offset_w = 8;		// nozzle offset from the left
 n_offset_l = 4.5;	// nozzle offset from the front
 n_d = 7/cos(30);	// nozzle (outermost) diameter
 hs_offset_w = 8;	// heater screw offset from the left
 hs_offset_l = 17.5;	// heater screw offset from the front
 hs_d = 5.7;		// heater screw diameter
 hs_t = 1.5; 		// heater screw head thickness
 ts_offset_l = 3.5;	// thermistor screw offset from the front
 ts_offset_h = 4.8;	// thermistor screw offset from the bottom
 ts_d = 7;		// thermistor screw diameter
 ts_t = 2.6;		// thermistor screw head thickness
 c_offset_l = 11.5;	// cartrdige offset from the from
 c_offset_h = 4;		// cartridge offset from the bottom
 c_d = 6.1;		// cartrdige diameter
 c_t = 1.7;		// cartridge protrusion length (thickness)
 c_tw = 4.3;		// thickness of the other cartridge end with wires
 
 sv=hs_t+ss;
 
 the_w = ss + max(c_tw,ts_t)+hb_w+c_t + ss;
 the_l = ss + hb_l + ss;
 the_h = sv + hb_h + ss;
 
+/* Nozzle stuff */
+n_protrude = 0.4;	// nozzle tip protrusion from silicone
+n_h1 = 3.6;		// nozzle cone base from the heater body (minimal)
+n_cone_h = 2;		// nozzle cone height
+n_cone_d2 = 1;		// pad diameter of the 0.4 nozzle (works up to 0.6); see
+			// http://wiki.e3d-online.com/images/3/3a/V6-NOZZLE-ALL.pdf
+n_cone_d1 = n_cone_h * tan(40) * 2 + n_cone_d2;
+codpiece_h = n_h1 + n_cone_h - n_protrude;
+
 use <bubbles.scad>;
-module heatershape(bubbled=true) {
+module heatershape(bubbled=true, codpiece=false) {
  m = n_offset_l-hb_d/2;
  module topholes(h) {
   hull() {
    for(sx=[-1,1]) for(sy=[-1,1])
     translate([hb_w/2+sx*(hb_w/2-m-hb_d/2),hb_l/2+sy*(hb_l/2-m-hb_d/2),0])
     cylinder(d=hb_d,h=h,$fn=24);
   }
   translate([-c_tw,c_offset_l-c_d/2,0])
   cube(size=[hb_w/2+c_tw,c_d,h]);
  }
  // main body and protrusion
  // body
  cube(size=[hb_w,hb_l,hb_h]);
  // protrusion
  translate([0,0,hb_h]) {
   // irrelevant, because we print upside-down: mo = m+max(c_t,c_tw)+ss; th=3*ss;
   mo = protrude/4; th = protrude/2;
-  translate([0,0,-1]) topholes(h=ss+protrude);
+  translate([0,0,-1]) topholes(h=ss+th);
+  if (!abro)
   translate([0,0,ss+protrude-mo-th]) hull() {
    topholes(h=layer_height);
    translate([-c_tw-ss,-ss,mo])
    cube(size=[the_w,the_l,th]);
   }
+  else
+   translate([-c_tw-ss,-ss,ss])
+    cube(size=[the_w,the_l,th]);
  }
  // nozzle
- translate([n_offset_w,n_offset_l,1]) mirror([0,0,1]) cylinder(d=n_d,h=sv+1,$fn=24);
+ translate([n_offset_w,n_offset_l,1]) mirror([0,0,1])
+  if (codpiece) {
+   mc_d2 = n_cone_d2 + n_protrude * tan(40) * 2;
+   intersection() {
+    cylinder(d = n_d, h = n_h1 + 1 + epsilon, $fn=24);
+    cylinder(d1 = n_d * 2, d2 = 0, h = n_h1 * 2 + 1, $fn=24);
+   }
+   translate([0, 0, n_h1 + 1])
+    cylinder(h = n_cone_h - n_protrude, d1 = n_cone_d1, d2 = mc_d2, $fn = 32);
+  } else
+   cylinder(d=n_d,h=sv+1,$fn=24);
  // heater screw
  translate([hs_offset_w,hs_offset_l,1]) mirror([0,0,1]) cylinder(d=hs_d,h=hs_t+1,$fn=24);
  // thermistor screw
  translate([1,ts_offset_l,ts_offset_h]) rotate([0,-90,0]) cylinder(d=ts_d,h=ts_t+1,$fn=24);
  // cartridge on the right
  translate([hb_w-1,c_offset_l,c_offset_h]) rotate([0,90,0]) cylinder(d=c_d,h=c_t+1,$fn=24);
  // cartrdige on the left
  translate([1,c_offset_l,c_offset_h]) rotate([0,-90,0]) cylinder(d=c_d,h=c_tw+1,$fn=24);
  translate([-c_tw,c_offset_l-c_d/2,c_offset_h]) cube(size=[c_tw+1,c_d,hb_h-c_offset_h]);
 
  if(bubbled) {
   for(y=[0,hb_l]) translate([0,y,0]) bubbles(size=[hb_w,ss/2,hb_h]);
   rotate([0,0,90]) bubbles(size=[hb_l,(c_tw+ss)/2,hb_h],d=(c_tw+ss)/2,s=1.1*(c_tw+ss)/2);
   translate([hb_w,0,0]) rotate([0,0,90]) bubbles(size=[hb_l,(c_t+ss)/2,hb_h],d=(c_t+ss),s=1.1*(c_t+ss));
   rotate([-90,0,0]) bubbles(size=[hb_w,sv/2,hb_l]);
  }
 }
 
 function vc(d,h) = PI*pow(d/2,2)*h;		// cylinder volume
 
 vol_ = the_w*the_l*the_h
  - hb_w*hb_l*hb_h					// heater block
  - vc(d=n_d,h=sv)					// nozzle
  - vc(d=hs_d,h=hs_t)					// heater screw
  - vc(d=ts_d,h=ts_t)					// thermistor_screw
  - vc(d=c_d,h=c_t)					// cartridge on the right
  - vc(d=c_d,h=c_tw)/2 - c_d*c_tw*(hb_h-c_offset_h)	// cartridge on the left
 ;
 vol = vol_*1.2;
 echo("volume",vol);
 
 use <view.scad>;
 use <mold.scad>;
 
-view="*";
+codpiece = true;
+view="inner";
 
 view(view=view,volume=vol) {
- mold(size=[the_w,the_l,the_h],s=ms,v_protrude=protrude,introffset=ss+c_offset_l);
- translate([ms+c_tw+ss,ms+ss,ms+sv]) heatershape();
- translate([ms+epsilon,ms+epsilon,ms+epsilon]) cube(size=[the_w-2*epsilon,the_l-2*epsilon,the_h-2*epsilon]);
+ cp_h = codpiece ? codpiece_h - sv : 0;
+ prt = abro ? protrude / 2 : protrude;
+ difference() {
+  union() {
+   mold(size=[the_w,the_l,the_h],s=ms,v_protrude=prt,introffset=ss+c_offset_l);
+   if (codpiece)
+    translate([0, 0, -cp_h])
+     cube([the_w + ms * 2, the_l + ms * 2, cp_h + epsilon]);
+  }
+  if (codpiece)
+   translate([ms + c_tw + ss + n_offset_w, ms + ss + n_offset_l, ms]) {
+    scale([1, 1, codpiece_h / (n_d + 2)])
+     sphere(d = n_d + 2, $fn = 64);
+   }
+ }
+ translate([ms+c_tw+ss,ms+ss,ms+sv]) heatershape(true, codpiece);
+ translate([ms+epsilon,ms+epsilon,ms+epsilon - cp_h])
+  cube(size=[the_w-2*epsilon,the_l-2*epsilon,the_h-2*epsilon + cp_h]);
 }
 /* vim:set ai sw=1: */
diff --git a/stuff.scad b/stuff.scad
index 26fb39f..922e702 100644
--- a/stuff.scad
+++ b/stuff.scad
@@ -1,6 +1,8 @@
 layer_height=0.2; extrusion_width=0.5;
 epsilon = .01;
 
 protrude=10;				// distance to protrude vertically
 ss=1;			                // minimum silicone shell thickness
 ms=1;					// mold shell thickness
+
+abro = 1;				// single component silicone
diff --git a/view.scad b/view.scad
index e3dcbee..cc996d6 100644
--- a/view.scad
+++ b/view.scad
@@ -1,33 +1,35 @@
+include <stuff.scad>;
 use <mixing.scad>;
 
 /**
  * view(...) {
  *  outer_mold();	// children(0);
  *  inner_shape();	// children(1);
  *  silicone();		// children(2);
  * }
  */
 module view(view,volume) {
  module cou() { color("palegreen",0.7) children(); }
  module cin() { color("silver",0.8) children(); }
  module csi() { color("salmon",0.5) children(); }
  module cmx() { color("gray",0.7) children(); }
  if(view=="outer") cou() children(0);
  else if(view=="inner") cin() children(1);
  else if(view=="mixplate") cmx() {
   mixing(volume=volume,what="vessel");
   translate([0,mixing_size(volume=volume)[1]/2+5,0])
   rotate([0,0,90]) mixing(volume=volume,what="splitter");
  }else if(view=="outcome") csi() {
   difference() {
    children(2);
    children([0:1]);
   }
  }else{
   cou() children(0); cin() children(1);
   csi() children(2);
+  if (!abro)
   translate([-mixing_size(volume=volume)[1]*2,0]) rotate([0,0,90])
   cmx() mixing(volume=volume,what="altogethernow");
  }
 }
 /* vim:set ai sw=1: */