increase effective hotend clearance

so that it corresponds to theoretical

1 files changed, 2 insertions, 1 deletions

diff --git a/fanduct.scad b/fanduct.scad
index 6407a96..49ab4c2 100644
--- a/fanduct.scad
+++ b/fanduct.scad
@@ -31,330 +31,331 @@ hotend_clearance = heater_clearance;
         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
 
         snapper_d = 8; snapper_overlap=0.2;// snip snap
 
 smooth_f = 120;
 
         type="circular"; // circular|3jets
         ductshape="square"; // square|round
         dual=false;     // dual or single
 
 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 single() {
    if(what=="in") {
     sh = fanduct_w+2*fanduct_shell; sv = fanduct_h+2*fanduct_shell;
     smax = max(sh,sv);
     rotate_extrude($fn=smooth_f)
      if(ductshape=="round")
       translate([sh/2+fanduct_ir,sv/2])
       scale([sh/smax,sv/smax])
       circle(d=smax,$fn=4*smax);
      else if(ductshape=="square")
       translate([fanduct_ir,0])
       square([sh,sv]);
    }else if(what=="out") {
     sh = fanduct_w; sv = fanduct_h;
     smax = max(sh,sv);
     rotate_extrude($fn=smooth_f)
      if(ductshape=="round")
       translate([sh/2+fanduct_shell+fanduct_ir,sv/2+fanduct_shell])
       scale([sh/smax,sv/smax])
       circle(d=smax,$fn=4*smax);
      else if(ductshape=="square")
       translate([fanduct_ir+fanduct_shell,fanduct_shell])
       union() {
        square([sh,sv/2]);
        translate([sh/2,sv/2])
        scale([sh/smax,sv/smax])
        circle(d=smax,$fn=36);
       }
    }
   }
   module dual() {
    module hulls(spots=dual_spots) {
     for(my=[0,1]) mirror([0,my,0]) for(pn=[0:1:len(spots)-2]) hull() {
      for(p=[spots[pn],spots[pn+1]]) translate(p) children();
     }
    }
    if(what=="in") {
     hulls() cylinder(d=fanduct_w+2*fanduct_shell,h=fanduct_h+2*fanduct_shell);
    }else if(what=="out") {
     sh = fanduct_w; sv = fanduct_h;
     smax = max(sh,sv);
     translate([0,0,fanduct_shell]) hulls() {
      cylinder(d=fanduct_w,h=fanduct_h/2);
      translate([0,0,fanduct_h/2])
      scale([sh/smax,sh/smax,sv/smax])
      intersection() {
       sphere(d=smax,$fn=36);
       translate([0,0,-1])
       cylinder(d=smax+2,h=smax+2,$fn=36);
      }
     }
    }
   }
 
   if(dual) 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 $fn
     difference() {
      hulls() {
       cylinder(d=fanduct_w+2*fanduct_shell,h=2*fanduct_shell+fanduct_h/2);
       translate([0,-nozzles_apart/2,-fanduct_elevation-fanduct_blowtarget]) sphere(d=.1);
      }
      translate([0,0,epsilon]) hull() for(my=[0:1]) mirror([0,my,0]) for(s=dual_spots) translate(s)
       mirror([0,0,1]) cylinder(d=fanduct_w+2*fanduct_shell+2,h=fanduct_elevation-fanduct_blowtarget+1);
      for(s=[-1,1]) translate([0,s*nozzles_apart/2,-1])
-      rotate([0,0,45]) cylinder(r=hotend_clearance,h=fanduct_h+2*fanduct_shell+2,$fn=4);
+      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], [0,0] ]);
       guideline([ [-far             ,inlet_w/2/4],
                   [-near            ,nozzles_apart/2] ]);
       guideline([ [-near-fanduct_w/3,nozzles_apart/2+near+fanduct_w/3] ]);
       guideline([ [0                ,nozzles_apart/2+near+fanduct_w/2] ]);
      }
     }
    }
   }
 
   if(dual) 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,
       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) {
    // 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: */