another: potentially even prettier pushfit arrangement

1 files changed, 17 insertions, 4 deletions

diff --git a/another.scad b/another.scad
index 6af68b6..4c4af5c 100644
--- a/another.scad
+++ b/another.scad
@@ -23,48 +23,49 @@ module the_extruder(
  // spring properties
          spring_d = 10, spring_lc = 9.6,        // spring diameter and compressed length
  // filament path properties
  filament_d = 1.75,
  filament_path_d = 2,
          filament_guide_d = 4,                  // PTFE filament guide diameter
  // knob properties
  knob_h = 10,
  knob_bore_l = 4,
  knob_indent_d = 4,
  knob_indents = 12,
  // spring tensioner
  st_nut_d = 9, st_nut_h = 4,
  st_screw_d = 5,
  st_thickshell = 8*extrusion_width, st_thinshell = 4*extrusion_width,
 
  // screw it
  mount_screw_d = 3.1, mount_screw_l = 20,
  mount_screwhead_d=6, mount_screwhead_h=3,
  idler_screw_d = 3,
  idler_screwhead_d=6, idler_screwhead_h=3,
 
  pf = pushfit_embeddest,
  pf_shell = max(3*layer_height,3*extrusion_width),
+ pf_smooth = true,
 
  // empty spaces
          idler_travel = 3,                      // how far should idler travel when pressed
  idler_clearance=1,
  pulley_clearance=2,
          lever_v_clearance=.7,                  // vertical clearance for the lever
  spring_d_clearance=1,
          protrusion_tolerance_h=.5,             // horizontal tolerance for the motor protrusion
          protrusion_tolerance_v=.5,             // vertical tolerance for the motor protrusion
  mount_screw_d_tolerance=.4,
  idler_v_tolerance=.5,
  knob_bore_d_tolerance=.6,
  st_nut_h_tolerance=.2,
  st_nut_d_tolerance=.2,/* TODO: make it st_nut_w_tolerance */
  st_screw_d_tolerance=.3,
 
  what="lever",  // lever|body|knob|springpad|*
  left=false,
  vitamins = true,
  supports = false, bridges = true,
  tensioner = true,
  debug = false
 ) {
  fnd = 2*PI; fnr = 2*fnd;
@@ -227,62 +228,74 @@ module the_extruder(
       if(!tensioner) finger_indent(d=lever_thickness-1,r=15); else {
        mirror([0,0,1]) {
         translate([0,0,st_thickshell])
         hull() for(o=[0,spring_d]) translate([0,-o,0])
         rotate([0,0,30])
         cylinder(d=st_nut_d+st_nut_d_tolerance,h=st_nut_h+st_nut_h_tolerance,$fn=6);
         translate([0,0,-1]) cylinder(d=st_screw_d+st_screw_d_tolerance,h=fsw+2,$fn=fnd*(st_screw_d+st_screw_d_tolerance));
         bigd = spring_d+spring_d_clearance;
         hf = (bigd-st_screw_d-st_screw_d_tolerance)/2;
         translate([0,0,st_thickshell+st_nut_h+st_nut_h_tolerance+st_thinshell-epsilon])
         cylinder(d1=st_screw_d+st_screw_d_tolerance,d2=bigd,
          h=hf+epsilon, $fn=fnd*bigd);
         translate([0,0,st_thickshell+st_nut_h+st_nut_h_tolerance+st_thinshell+hf-epsilon])
         cylinder(d=bigd,h=fsw+1,$fn=fnd*bigd);
        }
       }
      }
     } // translate
     
     // pushfit bracket
     translate([0,0,filament_elevation])
     rotate([0,0,45]) translate([pulley_d/2,0,0])
     rotate([-90,0,0])
     translate([0,0,mount_d/sqrt(2)/2+mount_screw_d-gearbox_d/2/*TODO:*/]) {
+     pfbl = pf_h(pf)+gearbox_d/2; //TODO:
+     if(pf_smooth) {
+      pfbd = pf_d(pf)+2*pf_shell;
+      hull() {
+       cylinder(d=pfbd,h=pfbl,$fn=pfbd*fnd);
+       translate([-epsilon/2,0,0]) {
+        cube(size=[epsilon,filament_elevation,pfbl-filament_elevation+pfbd/2]);
+        mirror([0,1,0])
+        cube(size=[epsilon,body_h-filament_elevation,pfbl-body_h+filament_elevation+pfbd/2]);
+       }//translate
+      }//hull
+     }else{
      pfb2a = pf_d(pf)+2*pf_shell; pfba = pfb2a/2;
      pfbd = pfb2a/cos(30);
      pfbs = pfb2a*tan(30);
-     pfbl = pf_h(pf)+gearbox_d/2/*TODO:*/;
      cylinder(d=pfbd,h=pfbl,$fn=6);
      translate([-pfbs/2,0,0]) {
       hull() {
        translate([0,-pfba,0]) cube(size=[pfbs,pfb2a,pfbl]);
        cube(size=[pfbs,filament_elevation,pfbl-filament_elevation+pfba]);
        mirror([0,1,0])
        cube(size=[pfbs,body_h-filament_elevation,pfbl-body_h+filament_elevation+pfba]);
-      }
-     }
-    }
+       }//hull
+      }//translate*/
+     }//if(pf_smooth)
+    }//translate rotate translate rotate translate
    }//union (first child of difference)
 
    // protrusion
    translate([0,0,-1])
    cylinder(d=protrusion_d+protrusion_tolerance_h,h=protrusion_h+protrusion_tolerance_v+1,$fn=fnd*(protrusion_d+protrusion_tolerance_h));
    // mount screw holes
    for(zr=[0:90:359]) rotate([0,0,zr]) translate([mount_d/2,0,0]) {
     translate([0,0,mount_screw_l-mounthole_depth/2-(bridges?layer_height:-epsilon)])
     mirror([0,0,1])
     cylinder(d=mount_screw_d+mount_screw_d_tolerance,
              h=mount_screw_l-mounthole_depth/2+1,
              $fn=fnd*(mount_screw_d+mount_screw_d_tolerance));
     translate([0,0,mount_screw_l-mounthole_depth/2])
     cylinder(d=mount_screwhead_d,h=body_h+1,$fn=fnd*mount_screwhead_d);
    }//for
    // pushfit
    translate([0,0,filament_elevation])
    rotate([0,0,45]) translate([pulley_d/2,0,0])
    rotate([-90,0,0])
    translate([0,0,mount_d/sqrt(2)/2+mount_screw_d+epsilon])
    rotate([0,0,180]) {
     pushfit(pf);
     cylinder(d=filament_guide_d,h=gearbox_d,center=true,$fn=fnd*filament_guide_d);
     translate([0,-filament_guide_d/2/sqrt(2),0])