belt-slot-cut-jig.scad

   1 // -*- C -*-
   2
   3 // todo
   4 //  various registration marks
   5 //   protrustions at ends at strap width and middle
   6 //   grooves on top face at 1/4,1/2,3/4 length and 1/2 width
   7
   8 crewpunch_slop = 0.3;
   9
  10 holder_min_wall = 2;
  11 holder_attach_near_wall = 3;
  12
  13 holder_attach_xsz = 5;
  14 holder_ctie_width = 4.0 + 0.5;
  15 holder_ctie_thick = 2.0 + 0.5;
  16 holder_attach_walls = 3;
  17 holder_attach_roof = 2.5;
  18
  19 jig_interval = 25;
  20 strap_width = 25;
  21 strap_thick = 3;
  22 edgewall_width = 3;
  23
  24 punch_travel = 8;
  25
  26 main_slop = 0.5;
  27
  28 jig_max_len = 160; // print diagonally
  29 //jig_max_len = 30;
  30
  31 // from careful measurement
  32
  33 crewpunch_shape =
  34   [[  6, [0.6, 6.0], [1.6, 12.3] ],
  35    [  8, [1.1, 6.2], [1.9, 12.5] ],
  36    [ 10, [1.6, 6.5], [2.1, 12.8] ],
  37    [ 12, [1.8, 6.6], [2.3, 12.7] ],
  38    [ 14, [2.1, 6.8], [2.6, 13.0] ],
  39    [ 16, [2.4, 6.9], [2.7, 13.2] ]];
  40
  41 crewpunch_shaft_max_y = 7.5;
  42
  43 crewpunch_systematic_size_error = +0.36;
  44
  45 crewpunch_min_y = 4.7 - crewpunch_systematic_size_error;
  46
  47 crewpunch_smallest_shape = crewpunch_shape[0];
  48 crewpunch_biggest_shape = crewpunch_shape[len(crewpunch_shape)-1];
  49
  50 // computed
  51
  52 attach_ysz = holder_attach_walls*2 + holder_ctie_width;
  53 holder_front_all = crewpunch_shaft_max_y - crewpunch_biggest_shape[1][1]
  54   + attach_ysz;
  55
  56 holder_block_zsz = crewpunch_biggest_shape[0] - crewpunch_smallest_shape[0];
  57 holder_xsz = crewpunch_biggest_shape[2][0] + crewpunch_biggest_shape[2][1] +
  58   holder_min_wall*2;
  59 crewpunch_biggest_y =
  60   crewpunch_biggest_shape[1][0] + crewpunch_biggest_shape[1][1];
  61 holder_ysz = crewpunch_biggest_y + holder_min_wall + holder_front_all;
  62
  63 attach_offset = 0.5 * (holder_front_all - holder_attach_near_wall);
  64
  65 jig_main_zsz = holder_block_zsz + punch_travel;
  66
  67 jig_ends_extra = 2;
  68
  69 jig_iters = (jig_max_len - jig_ends_extra) / jig_interval;
  70 echo(jig_iters);
  71
  72 // objects
  73
  74 module CrewPunch(){
  75   ourslop = crewpunch_slop - crewpunch_systematic_size_error;
  76   hull(){
  77     for(layer=crewpunch_shape){
  78       translate([0,0, layer[0]]){
  79         for(xind=[0,1]) //translate([xind?0:1,0,0])
  80           for(yind=[0,1]) //translate([0,yind?0.5:0,0])
  81             mirror([xind?1:0,0,0]) mirror([0,yind?0:1,0]){
  82               translate([-0.1,-0.1,-0.1])
  83                 cube([0.1 + layer[2][xind] + ourslop,
  84                       0.1 + layer[1][yind] + ourslop,
  85                       0.2]);
  86             }
  87       }
  88     }
  89   }
  90 }
  91
  92 module PunchHolder(cutouts=true){
  93   translate([-holder_xsz/2,
  94              -holder_ysz + holder_min_wall + crewpunch_biggest_y/2,
  95              0]){
  96     difference(){
  97       translate([0,attach_offset,0])
  98         cube([holder_xsz, holder_ysz - attach_offset, holder_block_zsz]);
  99       if (cutouts)
 100         translate([crewpunch_biggest_shape[2][1] + holder_min_wall,
 101                    crewpunch_biggest_shape[1][0] + holder_front_all,
 102                    -crewpunch_smallest_shape[0]])
 103           CrewPunch();
 104     }
 105     difference(){
 106       translate([holder_xsz/2 - holder_attach_xsz/2, 0, 0])
 107         cube([holder_attach_xsz,
 108               attach_ysz,
 109               holder_block_zsz + punch_travel
 110               + holder_ctie_thick + holder_attach_roof + 1]);
 111       if (cutouts)
 112         translate([-30,
 113                    holder_attach_walls,
 114                    holder_block_zsz + punch_travel])
 115           cube([60, holder_ctie_width, holder_ctie_thick]);
 116     }
 117   }
 118 }
 119
 120 module OneJig(){
 121   difference(){
 122     translate([-(jig_interval/2 + 1),
 123                -(strap_width/2 + edgewall_width) - attach_offset,
 124                -strap_thick])
 125       cube([jig_interval + 2,
 126             strap_width + edgewall_width*2 + attach_offset,
 127             jig_main_zsz + strap_thick]);
 128     minkowski(){
 129       cube([main_slop*2, main_slop*2, 50], center=true);
 130       PunchHolder(false);
 131     }
 132     translate([-100, -strap_width/2, -10])
 133       cube([200, strap_width, 10]);
 134   }
 135 }
 136
 137 module Jig(){
 138   for (i=[0:jig_iters-1]) {
 139     translate([jig_interval * i, 0, 0])
 140       OneJig();
 141   }
 142 }
 143
 144 module Demo(){
 145   %PunchHolder();
 146   Jig();
 147 }
 148
 149 //CrewPunch();
 150 //PunchHolder();
 151 //PunchHolder(false);
 152 //OneJig();
 153 //Jig();
 154 Demo();