-
Notifications
You must be signed in to change notification settings - Fork 0
/
ladder-foot.scad
377 lines (301 loc) · 13.8 KB
/
ladder-foot.scad
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100
101
102
103
104
105
106
107
108
109
110
111
112
113
114
115
116
117
118
119
120
121
122
123
124
125
126
127
128
129
130
131
132
133
134
135
136
137
138
139
140
141
142
143
144
145
146
147
148
149
150
151
152
153
154
155
156
157
158
159
160
161
162
163
164
165
166
167
168
169
170
171
172
173
174
175
176
177
178
179
180
181
182
183
184
185
186
187
188
189
190
191
192
193
194
195
196
197
198
199
200
201
202
203
204
205
206
207
208
209
210
211
212
213
214
215
216
217
218
219
220
221
222
223
224
225
226
227
228
229
230
231
232
233
234
235
236
237
238
239
240
241
242
243
244
245
246
247
248
249
250
251
252
253
254
255
256
257
258
259
260
261
262
263
264
265
266
267
268
269
270
271
272
273
274
275
276
277
278
279
280
281
282
283
284
285
286
287
288
289
290
291
292
293
294
295
296
297
298
299
300
301
302
303
304
305
306
307
308
309
310
311
312
313
314
315
316
317
318
319
320
321
322
323
324
325
326
327
328
329
330
331
332
333
334
335
336
337
338
339
340
341
342
343
344
345
346
347
348
349
350
351
352
353
354
355
356
357
358
359
360
361
362
363
364
365
366
367
368
369
370
371
372
373
374
375
376
377
/*--------------------------------------------------------*/
/* Ladder foot
/*
/* History:
/* - Created by:
/* Addie Janssen (November 15, 2020)
/* - Modified the zig-zag pattern to have a flat top
/* - Added validation of foot_radius value
/* - Number of zig-zags is not generated twice anymore
/*
/* - Based on:
/* Ladder foot factory / Leiterfuß-Fabrik
/* by Johann_LA (August 03, 2020)
/* https://www.thingiverse.com/thing:4560403
/* - Added zig-zag calculations
/*
/* - Which was based on:
/* Cap that Hole
/* by Zivbot (December 06, 2016)
/* https://www.thingiverse.com/thing:1943463
/*--------------------------------------------------------*/
/* [ Production or Validation ] */
// Turn on for validation during preview, TURN OFF FOR PRODUCTION
show_slice = "On"; // [On: On -- to be used for design/validation, Off: Off -- to be used for production]
/* [ Properties of the hole ] */
// Hole shape
hole_shape = "Rectangle"; // [Round, Square, Rectangle]
// HOLE Dimension 1 (if circular = diameter)
hole_dimension1 = 50; // [10:0.1:150]
// HOLE Dimension 2 (only for rectangle shape)
hole_dimension2 = 25; // [10:0.1:150]
// HOLE Corner Radius (for square/rectangle shapes)
hole_radius = 10; // [0:0.1:20]
// HOLE Depth (e.g. for a table, thickness of the board)
hole_depth = 30; // [2:0.1:100]
/* [ Properties of the plug ] */
// PLUG: plug length
plug_length = 25; // [2:0.1:100]
// PLUG: plug clearance inside hole
plug_clearance = 1; // [0:0.1:5]
// PLUG: plug material thickness
plug_thickness = 5.5; // [0.5:0.1:5]
// PLUG: Choose if you like snaps or fins
features = "Fins"; // [Fins: Fins - preferred choice, Snaps: Snaps - might be too instable, None]
// PLUG: Snaps/Fins protrusion of teeth (mm)
feature_length = 1.0; // [0.1:0.1:6]
// PLUG: Snaps/Fins height of teeth (mm)
feature_height = 1.5; // [0.1:0.1:6]
// PLUG FINS: Number of fins
fin_number = 5; // [1:1:6]
// PLUG SNAPS: Determines gaps size between snaps
snap_width_factor = 0.5; // [0.1:0.1:1]
/* [ Properties of the cover / top-end ] */
// COVER: thickness (mm) -- in skew case the minimal thickness
cover_thickness = 4; // [0.5:0.1:15]
// COVER: Overlap around hole
cover_offset = 3; // [0:0.1:30]
// COVER: Edge design
cover_edge = "ZigZag"; // [ZigZag, Chamfer, Round]
// COVER: Edge design ratio 1 (relative size of chamfer/fillet)
cover_edge_ratioV = 0.5; // [0:0.1:1]
// COVER: Edge design ratio 2 (relative size of chamfer/fillet)
cover_edge_ratioH = 0.1; // [0:0.1:1]
// COVER: Foot radius of Ziz-zag surface
foot_radius = 50;
// COVER: Number of Zig-zags
number_of_zigzag = 6;
// COVER: Height of a Zig-zag
height_zigzag = 3;
/* [ Quality settings ] */
// QUALITY: number of polygon facets
$fn = 40;
// QUALITY: steps in fillet cover design
fillet_steps = 6; // [4:1:15]
/* [Hidden] */
clearance = 0.01;
show_slice_ = (show_slice=="On");
snaps = features == "Snaps";
fins = features == "Fins";
/* testing area
hole_shape = "Rectangle"; // [Round, Square, Rectangle]
snap_width_factor = .5; // [0.1:0.1:1]
show_slice = "Off"; // [On, Off]
features = "Fins"; // [Snaps, Fins, None]
fin_number = 3; // [1:1:6]
hole_radius = 1; // [0:0.1:20]
*/
/*****************************************/
// Show hole
larger_dim = ((hole_shape=="Rectangle")?max(hole_dimension1, hole_dimension2) : hole_dimension1) + cover_offset;
smaller_dim = (hole_shape=="Rectangle")?min(hole_dimension1, hole_dimension2) : hole_dimension1;
largest_depth = max(hole_depth, plug_length)+cover_thickness+1;
// can't have corner radius exceed half the facet length
hole_radius_safe = (hole_radius > smaller_dim/2) ? (smaller_dim/2 - clearance) : hole_radius;
// can't have foot radius being smaller than hole dimension 1
foot_radius_safe = (foot_radius < hole_dimension1) ? hole_dimension1 : foot_radius;
// Illustrate the piece needing a cover
if (show_slice_)
%difference() {
translate([0,0,-hole_depth/2])
cube([larger_dim*1.5,larger_dim*1.5,hole_depth],center=true);
translate([0,0,-(hole_depth+clearance)])
linear_extrude(hole_depth+4*clearance)
gen_hole_shape(hole_dimension1, hole_dimension2, hole_radius_safe);
if (show_slice_)
translate([0,-larger_dim/2, -(largest_depth/2-clearance)])
cube([larger_dim*2.2, larger_dim*1, largest_depth+clearance*4], center=true);
}
// Generate the cap
difference() {
generate_cap();
color("Red")
if (show_slice_)
translate([0,-larger_dim/2-0.01, -(largest_depth/2)])
cube([larger_dim*1.8, larger_dim*1, largest_depth*6], center=true);
}
//********************** FUNCTIONS *****************************
module generate_cap () {
// calculation for the ladder foot
height_offset = sqrt(pow(foot_radius_safe,2)-pow((hole_dimension1)/2+cover_offset,2));
// what is the total angle we have to split into the zigzag?
half_angle = atan((hole_dimension1/2+cover_offset)/height_offset);
union() {
// Generate the zig-zag cap
if (cover_edge == "ZigZag") {
linear_extrude((1-cover_edge_ratioV)*cover_thickness + clearance, convexity = 4)
offset(r=cover_offset)
gen_hole_shape(hole_dimension1, hole_dimension2, hole_radius_safe);
points =
[
for (i = [-(number_of_zigzag/2):(number_of_zigzag/2)-1])
for (
pt = [
[(foot_radius_safe+0)*cos((i/(number_of_zigzag/2))*half_angle),
(foot_radius_safe+0)*sin((i/(number_of_zigzag/2))*half_angle)],
[
(foot_radius_safe+height_zigzag)*cos(((i+0.25)/(number_of_zigzag/2))*half_angle),
(foot_radius_safe+height_zigzag)*sin(((i+0.25)/(number_of_zigzag/2))*half_angle)
],
[
(foot_radius_safe+height_zigzag)*cos(((i+0.75)/(number_of_zigzag/2))*half_angle),
(foot_radius_safe+height_zigzag)*sin(((i+0.75)/(number_of_zigzag/2))*half_angle)
]
]
) pt,
[(foot_radius_safe+0)*cos(half_angle), (foot_radius_safe+0)*sin(half_angle)]
];
intersection() {
translate([0,0,cover_edge_ratioV*cover_thickness])
linear_extrude(100, convexity = 4)
offset(r=cover_offset)
gen_hole_shape(hole_dimension1, hole_dimension2, hole_radius_safe);
translate([0,(hole_dimension2/2+cover_offset),-height_offset+(1-cover_edge_ratioV)*cover_thickness])
rotate([0,-90,90])
linear_extrude(hole_dimension2+2*cover_offset)polygon(points);
}
}
// Generate cover with corner design
if (cover_edge == "Chamfer") {
linear_extrude((1-cover_edge_ratioV)*cover_thickness + clearance, convexity = 4)
offset(r=cover_offset)
gen_hole_shape(hole_dimension1, hole_dimension2, hole_radius_safe);
hull() { // convex hull
translate([0,0,(1-cover_edge_ratioV)*cover_thickness])
for (i = [0,1]) {
translate([0,0,i*cover_edge_ratioV*cover_thickness])
linear_extrude(0.01)
offset(r=cover_offset-i*cover_edge_ratioH*smaller_dim)
gen_hole_shape(hole_dimension1, hole_dimension2, hole_radius_safe);
}
}
}
else if (cover_edge == "Round") {
linear_extrude((1-cover_edge_ratioV)*cover_thickness + clearance, convexity = 4)
offset(r=cover_offset)
gen_hole_shape(hole_dimension1, hole_dimension2, hole_radius_safe);
hull() { // convex hull
translate([0,0,(1-cover_edge_ratioV)*cover_thickness])
for (i = [0:1/fillet_steps:1]) {
translate([0,0, sin(i*90)*cover_edge_ratioV*cover_thickness])
linear_extrude(0.01)
offset(r=cover_offset - (1-cos(i*90))*cover_edge_ratioH*smaller_dim)
gen_hole_shape(hole_dimension1, hole_dimension2, hole_radius_safe);
}
}
}
// Generate plug
difference() {
union() {
translate([0,0,-(plug_length) + clearance])
linear_extrude(plug_length+clearance, convexity = 4)
offset(r=-plug_clearance)
gen_hole_shape(hole_dimension1, hole_dimension2, hole_radius_safe);
// Generate plug fins
//translate([0,0,-(hole_depth) + clearance])
if (fins) {
d = plug_length/(fin_number+1);
for (i = [1:fin_number]) {
translate([0,0,-(d*i + 0.3*d)])
hull() {
linear_extrude(0.01)
offset(r=-plug_clearance)
gen_hole_shape(hole_dimension1, hole_dimension2, hole_radius_safe);
translate([0,0,feature_height])
linear_extrude(0.2)
offset(r=feature_length-plug_clearance)
gen_hole_shape(hole_dimension1, hole_dimension2, hole_radius_safe);
}
}
}
if (snaps) {
translate([0,0,-plug_length])
hull() {
linear_extrude(0.01)
offset(r=-plug_clearance)
gen_hole_shape(hole_dimension1, hole_dimension2, hole_radius_safe);
translate([0,0,feature_height])
linear_extrude(0.2)
offset(r=feature_length-plug_clearance)
gen_hole_shape(hole_dimension1, hole_dimension2, hole_radius_safe);
}
}
}
// remove inner volume of plug
translate([0,0,-(plug_length) - clearance])
linear_extrude(plug_length+2*clearance, convexity = 4)
offset(r=-(plug_clearance+plug_thickness))
gen_hole_shape(hole_dimension1, hole_dimension2, hole_radius_safe);
// remove edge chamfer
if (!snaps)
translate([0,0,-(plug_length) ])
difference() {
linear_extrude(plug_thickness/2 + clearance )
offset(r=-plug_clearance + clearance)
gen_hole_shape(hole_dimension1, hole_dimension2, hole_radius_safe);
hull() {
linear_extrude(0.01)
offset(r=-plug_clearance -(plug_thickness/2) + 2*clearance)
gen_hole_shape(hole_dimension1, hole_dimension2, hole_radius_safe);
translate([0,0,plug_thickness/2 + 2*clearance ])
linear_extrude(0.01)
offset(r=-plug_clearance)
gen_hole_shape(hole_dimension1, hole_dimension2, hole_radius_safe);
}
}
// remove snap gaps
if (snaps) {
if (hole_shape == "Square") {
factor = 0.5+snap_width_factor*0.4;
rotate([0,0,45])
for (i = [1:4]) {
rotate([0,0,i*360/4])
translate([factor*hole_dimension1/sin(45),0,-(plug_length/2 + clearance)])
rotate([0,0,45])
cube([hole_dimension1,hole_dimension1,plug_length+4*clearance], center=true);
}
}
else if (hole_shape == "Round") {
factor = 0.48+snap_width_factor*0.3;
rotate([0,0,45])
for (i = [1:4]) {
rotate([0,0,i*360/4])
translate([factor*hole_dimension1/sin(45),0,-(plug_length/2 + clearance)])
rotate([0,0,45])
cube([hole_dimension1,hole_dimension1,plug_length+4*clearance], center=true);
}
}
else { // Rectangle
factor = 0.5+0.4*snap_width_factor;
translate([-factor*hole_dimension1,factor*hole_dimension2,-(plug_length/2 + clearance)])
cube([hole_dimension1,hole_dimension2,plug_length+4*clearance], center=true);
translate([factor*hole_dimension1,factor*hole_dimension2,-(plug_length/2 + clearance)])
cube([hole_dimension1,hole_dimension2,plug_length+4*clearance], center=true);
translate([-factor*hole_dimension1,-factor*hole_dimension2,-(plug_length/2 + clearance)])
cube([hole_dimension1,hole_dimension2,plug_length+4*clearance], center=true);
translate([factor*hole_dimension1,-factor*hole_dimension2,-(plug_length/2 + clearance)])
cube([hole_dimension1,hole_dimension2,plug_length+4*clearance], center=true);
}
}
}
}
}
module gen_hole_shape ( d1, d2, r1 ) {
if (hole_shape == "Round") {
circle(d=d1);
}
else {
d1b = d1 - 2*r1;
d2b = ((hole_shape == "Square")?d1:d2) - 2*r1;
translate([-d1b/2,-d2b/2,0]) {
if (r1 > 0)
minkowski() {
circle(r1);
square([d1b,d2b]);
}
else {
square([d1b,d2b]);
}
}
}
}