more advanced chimera hotend

1 files changed, 74 insertions, 1 deletions

diff --git a/fanduct.scad b/fanduct.scad
index ba63717..2bc5623 100644
--- a/fanduct.scad
+++ b/fanduct.scad
@@ -1,422 +1,495 @@
 use <snapper.scad>;
 extrusion_width=.5; layer_height=.2;		// print parameters
 
 epsilon=.005;		// for finer cuts
 
 type="simple"; 	// circular|3jets
 ductshape="square"; 	// square|round
 dual=true;		// dual or single
 
 nozzles_apart = 18;		// distance between nozzles for dual hotend
 space_behind_nozzle = 10;	// space behind the nozzle where we're allowed to go
 				// without the fear of hitting carriage
 
 inlet_w = 12.5;		// inlet width
 inlet_h = 17;		// inlet height
 inlet_short_l = 7;	// inlet length of protrusion (or depth of intrusion:))
 inlet_away = 15;	// how far away inlet is
 
 inlet_long_l = inlet_short_l+inlet_h;
 function hypothenuse(a,b) = sqrt(pow(a,2)+pow(b,2));
 
 silicone_shell = 2;
 heater_clearance = dual
        ? max(20,15.5) - 4.5 + silicone_shell
        : max(
 	hypothenuse(16/2     +silicone_shell, 20-4.5 +silicone_shell),	// E3D v6
 	hypothenuse(11.5-4.5 +silicone_shell, 15.5   +silicone_shell)	// E3D volcano
        );
 
 fanduct_elevation = 3;							// fanduct elevation above nozzle tip
 fanduct_blowtarget = -2;						// what to blow at
 fanduct_h = 6;								// inner height of the duct
 fanduct_w = 7;								// inner width of the duct
 fanduct_shell=1.2;							// shell thickness
 fanduct_ir = heater_clearance+5;					// inner radius
 
 jet_angle = 60-2;		// angular width of the jet
 
 hotend_clearance = heater_clearance;
 
 snapper_d = 8; snapper_overlap=0.2;	// snip snap
 
 draft=true;
 smooth_f = draft? 30 : 120;
 
 to_midduct = fanduct_ir+fanduct_shell+fanduct_w/2;
 dual_spots = [ [+space_behind_nozzle, -(to_midduct+nozzles_apart/2)],
 	       [-         to_midduct, -(to_midduct+nozzles_apart/2)],
 	       [-         to_midduct, 0] ];
 
 module fanduct(type=type,ductshape=ductshape,dual=dual) {
  //	***	duct is all around!
 
  module duct(what) {
   module ductshape(what,sh,sv,r) {
    smax = max(sh,sv);
    translate([what=="in"?0:fanduct_shell,what=="in"?0:fanduct_shell])
    if(ductshape=="round") {
     translate([sh/2+r,sv/2])
     scale([sh/smax,sv/smax])
     circle(d=smax,$fn=4*smax);
    }else if(ductshape=="square") {
     translate([r,0])
     if(what=="in")
      square([sh,sv]);
     else if(what=="out") union() {
      square([sh,sv/2]);
      translate([sh/2,sv/2])
      scale([sh/smax,sv/smax])
      circle(d=smax,$fn=4*smax);
     }
    }
   }
   module single() {
    if(what=="in") {
     sh = fanduct_w+2*fanduct_shell; sv = fanduct_h+2*fanduct_shell;
     rotate_extrude($fn=smooth_f)
     ductshape(what=what,sh=sh,sv=sv,r=fanduct_ir);
    }else if(what=="out") {
     sh = fanduct_w; sv = fanduct_h;
     smax = max(sh,sv);
     rotate_extrude($fn=smooth_f)
     ductshape(what=what,sh=sh,sv=sv,r=fanduct_ir);
    }
   }
   module dual() {
    module hulls(spots=dual_spots) {
     for(my=[0,1]) mirror([0,my,0]) for(pn=[0:1:len(spots)-2]) hull() {
      for(p=[spots[pn],spots[pn+1]]) translate(p) children();
     }
    }
    if(what=="in") {
     hulls() cylinder(d=fanduct_w+2*fanduct_shell,h=fanduct_h+2*fanduct_shell);
    }else if(what=="out") {
     sh = fanduct_w; sv = fanduct_h;
     smax = max(sh,sv);
     translate([0,0,fanduct_shell]) hulls() {
      cylinder(d=fanduct_w,h=fanduct_h/2);
      translate([0,0,fanduct_h/2])
      scale([sh/smax,sh/smax,sv/smax])
      intersection() {
       sphere(d=smax,$fn=36);
       translate([0,0,-1])
       cylinder(d=smax+2,h=smax+2,$fn=36);
      }
     }
    }
   }
   module dual_simple() {
    for(my=[0,1]) mirror([0,my,0])
    if(what=="in") {
     sh = fanduct_w+2*fanduct_shell; sv = fanduct_h+2*fanduct_shell;
     translate([0,nozzles_apart/2,0])
     intersection() {
      rotate_extrude($fn=smooth_f)
       translate([fanduct_ir,0]) square([sh,sv]);
      translate([-fanduct_ir-sh-1,0,-1])
      cube(size=[fanduct_ir+sh+2,fanduct_ir+sh+2,sv+2]);
     }
     translate([-fanduct_ir-sh,-epsilon,0])
     cube(size=[sh,nozzles_apart/2+2*epsilon,sv]);
     translate([0,sh/2+fanduct_ir+nozzles_apart/2,0]) cylinder(d=sh,h=sv,$fn=36);
    }else if(what=="out") {
     sh = fanduct_w; sv = fanduct_h;
     translate([0,nozzles_apart/2,fanduct_shell])
     intersection() {
      rotate_extrude($fn=smooth_f)
       translate([fanduct_ir+fanduct_shell,0]) square([sh,sv]);
      translate([-fanduct_ir-2*fanduct_shell-sh-1,-1,0])
      cube(size=[fanduct_ir+2*fanduct_shell+sh+2,fanduct_ir+2*fanduct_shell+sh+2,sv]);
     }
     translate([-fanduct_ir-fanduct_shell-sh,-epsilon,fanduct_shell])
     cube(size=[sh,nozzles_apart/2+2*epsilon,sv]);
     translate([0,sh/2+fanduct_shell+fanduct_ir+nozzles_apart/2,fanduct_shell])
     cylinder(d=sh,h=sv,$fn=36);
    }
   }
+  module dual_complex() {
+   for(my=[0,1]) mirror([0,my,0])
+    if(what=="in") {
+     sh = fanduct_w+2*fanduct_shell;
+     sv = fanduct_h+2*fanduct_shell;
+     for(mx=[0,1]) mirror([mx,0,0])
+     mirror([0,1,0]) rotate([90,0,0])
+     translate([0,0,-1])
+     linear_extrude(height=nozzles_apart/2+1+epsilon)
+     ductshape(sh=sh,sv=sv,r=fanduct_ir,what=what);
+     translate([0,nozzles_apart/2,0])
+     difference() {
+      rotate_extrude($fn=smooth_f)
+      ductshape(sh=sh,sv=sv,r=fanduct_ir,what=what);
+      mirror([0,1,0]) translate([-fanduct_ir-sh-1,0,-1])
+      cube(size=[2*(fanduct_ir+sh+1),fanduct_ir+sh+1,sv+2]);
+     }
+    }else{
+     sh = fanduct_w; sv = fanduct_h;
+     for(mx=[0,1]) mirror([mx,0,0])
+     mirror([0,1,0]) rotate([90,0,0])
+     translate([0,0,-1])
+     linear_extrude(height=nozzles_apart/2+1+epsilon)
+     ductshape(sh=sh,sv=sv,r=fanduct_ir,what=what);
+     translate([0,nozzles_apart/2,0])
+     difference() {
+      rotate_extrude($fn=smooth_f)
+      ductshape(sh=sh,sv=sv,r=fanduct_ir,what=what);
+      mirror([0,1,0]) translate([-fanduct_ir-sh-1,0,-1])
+      cube(size=[2*(fanduct_ir+sh+1),fanduct_ir+sh+1,sv+2]);
+     }
+    }
+  }
 
   if(dual) {
    if(type=="simple")
     dual_simple();
+   else if(type=="jets")
+    dual_complex();
    else dual();
   }else single();
  }
 
  //	***	bumps for easier position adjustments in line with hotend
  module marks(what) {
   if(what=="in") {
    for(y=[-1,1]) translate([0,dual?y*nozzles_apart/2:0,0])
     hull() for(z=[0,-fanduct_shell-fanduct_h/2])
      translate([0,y*(fanduct_ir+fanduct_shell+fanduct_w/2),fanduct_shell*2+fanduct_h+z])
      rotate([90,0,0]) {
       cylinder(r=fanduct_shell,h=fanduct_w,center=true,$fn=30);
       for(z=[-1,1]) translate([0,0,z*fanduct_w/2])
        sphere(r=fanduct_shell,$fn=30);
      }
   }
  }
 
  //	***	output
  module output(what,type=type) {
   module guideline(xyxy) {
    module pin(xy) {
     translate([xy[0],xy[1],0])
     cylinder(d=2*extrusion_width,h=2*fanduct_shell+inlet_h,$fn=6);
    }
    xyxyxy=concat(xyxy,[[0,dual?nozzles_apart/2:0]]);
    for(i=[0:1:len(xyxyxy)-2])
     hull() for(j=[i,i+1]) pin(xyxyxy[j]);
   }
 
   module circus(what) {
    if(what=="in") {
     difference() {
      rotate_extrude($fn=smooth_f)
       polygon([
        [0,-fanduct_elevation+fanduct_blowtarget+epsilon],
        [fanduct_ir+fanduct_shell,fanduct_shell+fanduct_h/2],
        [fanduct_ir+fanduct_shell+fanduct_w/2,0],
        [0,-fanduct_elevation+fanduct_blowtarget-epsilon]]);
      translate([0,0,-1])
      cylinder(r=hotend_clearance,h=fanduct_h+2*fanduct_shell+2,$fn=smooth_f);
      mirror([0,0,1])
      translate([0,0,-epsilon])
      cylinder(r=fanduct_ir+2*fanduct_shell+fanduct_w+1,h=fanduct_elevation+.1+2);
     }
    }else if(what=="out") {
     rotate_extrude($fn=smooth_f)
     polygon([
      [0,-fanduct_elevation+fanduct_blowtarget+epsilon],
      [fanduct_ir+fanduct_shell+1,fanduct_h/2],
      [fanduct_ir+fanduct_w/2+fanduct_shell+1,fanduct_shell],
      [0,-fanduct_elevation+fanduct_blowtarget-epsilon]]);
    }else if(what=="airguides") {
     inr = fanduct_ir+fanduct_shell; our = inr+fanduct_w;
     union() {
      for(my=[0,1]) mirror([0,my,0]) {
       guideline([
        [-our,inlet_w/6],
        [-inr*sin(60),inr*cos(60)]
       ]);
       a0=30; as=15; a1=180;
       for(a=[a0+as:as:a1]) {
        f = as/(a1-a+as);
        rotate([0,0,a]) guideline([[-inr-fanduct_w*f,0]]);
       }
       guideline([
        [-our+fanduct_w*cos(30)*3/4,fanduct_w*sin(30)*3/4],
        [-inr*cos(10),inr*sin(10)]
       ]);
      }
     }/*union*/
    }/*airguides*/
   }
 
   module jets(what) {
    od = fanduct_h*2/3+fanduct_shell;
    md = fanduct_ir+fanduct_shell+fanduct_w/2;
    jww = 2*md*sin(jet_angle/2);
    difference() {
     for(a=[0:120:359]) rotate([0,0,a]) {
      if(what=="in") {
       hull() {
        intersection() {
 	translate([md-fanduct_w/2,-jww/2,0])
 	cube(size=[fanduct_shell+fanduct_w/2,jww,od]);
 	duct(what=what);
        }
        translate([0,0,-fanduct_elevation]) sphere(r=.5);
       }
      }else if(what=="out") {
       hull() {
        intersection() {
 	translate([md-fanduct_w/2,-jww/2+fanduct_shell,fanduct_shell])
 	cube(size=[fanduct_w/2,jww-2*fanduct_shell,od-2*fanduct_shell]);
 	duct(what=what);
        }
        translate([0,0,-fanduct_elevation]) sphere(r=.2);
       }
      }
     }
     if(what=="in") {
      translate([0,0,-fanduct_elevation-2+epsilon])
      cylinder(r=fanduct_ir+fanduct_shell*2+fanduct_w+1,h=fanduct_elevation+2);
      translate([0,0,-hotend_clearance])
      rotate([0,0,30])
      cylinder(r1=hotend_clearance*2,r2=0,h=hotend_clearance*2,$fn=6);
     }
    }
   }
 
   module dual(what=what) {
    module hulls(spots=dual_spots) {
     for(my=[0,1]) mirror([0,my,0]) for(pn=[0:1:len(spots)-2]) hull() {
      for(p=[spots[pn],spots[pn+1]]) translate(p) children(0);
      children([1:$children-1]);
     }
    }
    if(what=="in") {
     cfn= 4; // clearance cutout $fn
     difference() {
      hulls() {
       cylinder(d=fanduct_w+2*fanduct_shell,h=2*fanduct_shell+fanduct_h/2);
       translate([0,-nozzles_apart/2,-fanduct_elevation-fanduct_blowtarget]) sphere(d=.1);
      }
      translate([0,0,epsilon]) hull() for(my=[0:1]) mirror([0,my,0]) for(s=dual_spots) translate(s)
       mirror([0,0,1]) cylinder(d=fanduct_w+2*fanduct_shell+2,h=fanduct_elevation-fanduct_blowtarget+1);
      for(s=[-1,1]) translate([0,s*nozzles_apart/2,-1])
       rotate([0,0,180/cfn]) cylinder(r=hotend_clearance/cos(180/cfn),h=fanduct_h+2*fanduct_shell+2,$fn=cfn);
     }
    }else if(what=="out") {
     hulls() {
      translate([0,0,fanduct_shell]) cylinder(d=fanduct_w,h=fanduct_h/2-fanduct_shell/2);
      translate([0,-nozzles_apart/2,-fanduct_elevation+fanduct_blowtarget]) sphere(d=.1);
     }
    }else if(what=="airguides") {
     far = fanduct_ir+fanduct_shell+fanduct_w;
     near = fanduct_ir;
     union() {
      for(my=[0,1]) mirror([0,my,0]) {
       guideline([ [-far             ,0], [0, nozzles_apart/8] ]);
       guideline([ [-far             ,inlet_w/2/4 ],
                   [-near            ,to_midduct/2] ]);
       guideline([ [-near-fanduct_w/3,  to_midduct/2       ],
                   [-near            ,nozzles_apart/2+near ] ]);
       guideline([ [0                ,nozzles_apart/2+near+fanduct_w*space_behind_nozzle/to_midduct] ]);
      }
     }
    }
   }
 
+  module dual_jets(what=what) {
+   od=fanduct_h*2/3+fanduct_shell;
+   md=fanduct_ir+fanduct_shell+fanduct_w/2;
+   jww = 2*md*sin(jet_angle/2);
+   difference() {
+    for(my=[0,1]) mirror([0,my,0])
+    translate([0,nozzles_apart/2,0])
+    for(a=[45,135]) rotate([0,0,a])
+    if(what=="in") {
+     hull() {
+      intersection() {
+       translate([md-fanduct_w/2,-jww/2,0])
+       cube(size=[fanduct_shell+fanduct_w/2,jww,od]);
+       rotate([0,0,-a]) translate([0,-nozzles_apart/2,0]) duct(what=what);
+      } // intersection
+      translate([0,0,-fanduct_elevation]) sphere(r=.5);
+     } // hull
+    }else if(what=="out") {
+     hull() {
+      intersection() {
+       translate([md-fanduct_w/2,-jww/2+fanduct_shell,fanduct_shell])
+       cube(size=[fanduct_w/2,jww-2*fanduct_shell,od-2*fanduct_shell]);
+       rotate([0,0,-a]) translate([0,-nozzles_apart/2,0]) duct(what=what);
+      } // intersection
+      translate([0,0,-fanduct_elevation]) sphere(r=.5);
+     } // hull
+    } // what=="out"
+    if(what=="in") {
+     translate([0,0,-fanduct_elevation/2-1+epsilon])
+     cube(size=[2*(fanduct_ir+2*fanduct_shell+fanduct_w+1),nozzles_apart+2*(fanduct_ir+2*fanduct_shell+fanduct_w+1),fanduct_elevation+2],center=true);
+     for(my=[0,1]) mirror([0,my,0])
+      translate([0,nozzles_apart/2,-hotend_clearance])
+      cylinder(r1=hotend_clearance*2,r2=0,h=hotend_clearance*2,$fn=4);
+    }
+   } // difference
+  }
+
   module dual_simple(what=what) {
    for(my=[0:1]) mirror([0,my,0]) if(what=="in") {
     difference() {
      hull() {
       translate([0,nozzles_apart/2+fanduct_ir+fanduct_shell+fanduct_w/2,0])
       cylinder(d=fanduct_w+2*fanduct_shell,h=fanduct_h*2/3+2*fanduct_shell);
       translate([0,nozzles_apart/2,-fanduct_elevation+fanduct_blowtarget])
       rotate([0,90,0]) cylinder(r=.5,h=fanduct_w*2,center=true);
      }
      rr = 2*(fanduct_ir+fanduct_shell*2+fanduct_w+2);
      translate([-rr/2,0,0]) mirror([0,0,1]) cube(size=[rr,rr,rr]);
     }
    }else if(what=="out") {
     hull() {
      translate([0,nozzles_apart/2+fanduct_ir+fanduct_shell+fanduct_w/2,fanduct_shell])
      cylinder(d=fanduct_w,h=fanduct_h*2/3);
      translate([0,nozzles_apart/2,-fanduct_elevation+fanduct_blowtarget])
      rotate([0,90,0]) cylinder(d=.5,h=fanduct_w*2,center=true);
     }
    }
   }
 
   if(dual) {
    if(type=="simple") dual_simple(what);
+   else if(type=="jets") dual_jets(what);
    else dual(what);
   }else if(type=="circular") circus(what);
   else if(type=="3jets") jets(what);
  }
 
  //	***	air intake
  module intake(what) {
   module placeit() {
    translate([-fanduct_ir-2*fanduct_shell-fanduct_w-inlet_away,0,fanduct_shell])
    rotate([0,-90,0])
    children();
   }
   if(what=="in") {
    placeit() translate([0,-inlet_w/2,0]) {
     difference() {
      cube(size=[inlet_h,inlet_w,inlet_long_l+fanduct_shell]); translate([inlet_h+fanduct_shell,0,inlet_long_l+fanduct_shell])
      rotate([-90,0,0])
      translate([0,0,-1])
      cylinder(r=inlet_h,h=inlet_w+2*fanduct_shell+2,$fn=inlet_h*4);
     }
     // supports
     for(i=[-1,0,1])
      translate([-fanduct_shell,
       (i+1)*(inlet_w-extrusion_width)/2,
      -inlet_away-fanduct_w/2])
      cube(size=[fanduct_shell+1,
       extrusion_width,
       inlet_long_l+fanduct_shell+inlet_away+fanduct_w/2]);
    }
    hull() {
     placeit() translate([-fanduct_shell,-inlet_w/2-fanduct_shell,0])
     cube(size=[inlet_h+2*fanduct_shell,inlet_w+2*fanduct_shell,fanduct_shell]);
     translate([-fanduct_ir-fanduct_shell-fanduct_w/2,0,0])
     translate([0,-inlet_w/2-fanduct_shell/2,0])
     cube(size=[1,inlet_w+fanduct_shell,fanduct_shell*2+fanduct_h]);
    }
   }else if(what=="out") {
    placeit() translate([fanduct_shell,-inlet_w/2+fanduct_shell,0])
    cube(size=[inlet_h-2*fanduct_shell,inlet_w-2*fanduct_shell,inlet_long_l+fanduct_shell+1]);
    hull() {
     placeit() translate([fanduct_shell,-inlet_w/2+fanduct_shell,0])
     cube(size=[inlet_h-2*fanduct_shell,inlet_w-2*fanduct_shell,fanduct_shell]);
     translate([-fanduct_ir-fanduct_shell-fanduct_w/2,0,fanduct_shell])
     translate([0,-inlet_w/2+fanduct_shell,0])
     cube(size=[1,inlet_w-2*fanduct_shell,fanduct_h]);
    }
   }
  }
 
  //	***	DUCT TAILS!!! WOO-OO! (every day they're out there making duct tails…)
  module tails(what) {
-  if(dual) {
+  if(dual && type=="simple") {
    // XXX: not sure if it will ever be
   }else{
    if(what=="in") {
     for(mx=[0,1]) mirror([mx,0,0])
     translate([fanduct_ir+fanduct_shell+fanduct_w/2,0,fanduct_shell+fanduct_h/2])
     rotate([90,0,90])
     translate([0,0,-snapper_d/2])
     snapper(d=snapper_d,o=snapper_overlap,side=0,l=fanduct_h*3/2+fanduct_shell);
    }
   }
  }
 
  module parts(what) {
   union() {
    duct(what);
    marks(what);
    output(what);
    intake(what);
    tails(what);
   }
  }
 
  difference() {
   parts("in");
   parts("out");
  }
  intersection() {
   union() {
    output("airguides");
    sphere(d=epsilon);
   }
   union() {
    duct("in"); output("in"); intake("in");
   }
  }
 }
 
 view="*"; // hcut|vcut|*
 
 hinfinity=4*(fanduct_ir+fanduct_shell*2+fanduct_w+inlet_away);
 vinfinity=2*(fanduct_shell*2+fanduct_h+inlet_h);
 if(view=="hcut") {
  difference() {
   fanduct();
   translate([-hinfinity/2,-hinfinity/2,fanduct_shell+fanduct_h/2])
   cube(size=[hinfinity,hinfinity,vinfinity]);
  }
 }else if(view=="vcut") {
  difference() {
   fanduct();
   translate([-hinfinity/2,0,-vinfinity/2])
   cube(size=[hinfinity,hinfinity,vinfinity]);
  }
 }else fanduct();
 /* vim:set sw=1 ai: */