4 // 3D design for filament spools to hold coils as supplied by Faberdashery
8 // Copyright 2012,2013,2016 Ian Jackson
10 // This work is free software: you can redistribute it and/or modify
11 // it under the terms of the GNU General Public License as published by
12 // the Free Software Foundation, either version 3 of the License, or
13 // (at your option) any later version.
15 // This work is distributed in the hope that it will be useful,
16 // but WITHOUT ANY WARRANTY; without even the implied warranty of
17 // MERCHANTABILITY or FITNESS FOR A PARTICULAR PURPOSE. See the
18 // GNU General Public License for more details.
20 // You should have received a copy of the GNU General Public License
21 // along with this work. If not, see <http://www.gnu.org/licenses/>
25 // Each spool is a hub with 3 or 4 arms. Each arm has a cup for
26 // holding the filament. The effective diameter can be adjusted by
27 // setting the cup into a different seat in the arm. The cups are
28 // held on with simple clips, so the filement coil can easily be
29 // removed and replaced.
31 // This file (and its includes) can generate:
33 // - Heavy duty 4-armed spool suitable for holding a 100m
34 // Faberdashery coil on the spool arm of a Lulzbot TAZ-5.
39 // And print following parts
42 // FilamentCup x 4 (or FilamentCupPair x 2)
43 // CupSecuringClup x 4
45 // You will also need 4 x M4 machine screws and nuts
47 // - Light duty 3-armed spool suitable for up to around 30m
48 // of Faberdashery 2.85mm PLA.
53 // And print following parts
56 // FilamentCup x 3 (or FilamentCup + FilamentCupPair)
57 // CupSecuringClup x 3
58 // TowerDoveClipPin x 6
60 // When assembling, insert one TowerDoveClipPin from each side,
61 // joining each ArmEnd to the Hub with two TowerDoveClipPins.
62 // Modest force with pliers is good to seat them properly.
64 // (note that the light duty and heavy duty CupSecuringClips
65 // are slightly different)
67 // For the above, I generally used the Cura `Standard' PLA profile.
69 // - Storage arm suitable for screwing to walls, bookshelves,
70 // etc. (requires non-countersunk M4 screws); will hold two
71 // heavy duty spools each with a 100m coil.
76 // And print one of these, according to taste
80 // NB that the `light duty' version of this is shorter and
81 // will only take two `light duty' spools.
83 // For the above, I used the Cura `High detail' PLA profile because
84 // I wanted it pretty, but the `Standard' profile should do fine.
86 // - Spool (in many parts) for handing 1.75mm filament, printable
87 // on, and with parts for mounting on, a Reprappro Huxley.
91 lightduty=false; // or true
97 function selsz(sm,lt,lg) = fdia < 2 ? sm : lightduty ? lt : lg;
98 function usedove() = selsz(true,true,false);
100 num_arms = selsz(3,3,4);
102 channelslop=selsz(slop,0.75,slop);
105 hubeffrad = selsz(30, 82, 40);
106 hubbigrad = selsz(20, 38, 38);
107 hublwidth = selsz(3, 2.5, 4);
110 hubaxlerad = selsz(5, 28/2, 28/2);
111 totalheightfromtower = 240;
112 axletowerfudgebend = 0;
113 axleaxlefudgebend = 3;
118 prongthick=selsz(5,4,5);
119 prongwidth=selsz(5,4,5);
121 prongribheight=selsz(0,0,4);
124 ratchettoothheight=5;
125 ratchettoothsmoothr=1;
126 ratchettoothslope=0.75;
128 cupwidth=selsz(40,25,50);
129 cupheight=selsz(55,25,55);
131 cupstrong_dx=selsz(0,0,-10);
142 stalklength=selsz(35,25,55);
147 overclipcupnextgap=selsz(20,15,20);
149 hubaxlelen = selsz(25, 62.5, 77.5);
152 overclipsmaller=-2.5;
159 armendwallthick=selsz(2.5, 1.8, 2.5);
160 armendbasethick=selsz(1.2, 1.2, 1.2);
162 axlehorizoffset = 12.5;
163 axlevertheight = 100;
172 washerthinthick = 0.8;
173 washerverythinthick = 0.4;
174 washerrad = hubaxlerad + 7.5;
175 frictionwasherarmwidth = 3;
176 frictionwasherextrapush = 1.0;
178 ratchetpawl=ratchetstep-ratchettooth-bigslop*2;
180 nondove_armhole_x = 32;
181 nondove_armhole_hole = 4 + 0.8;
182 nondove_armhole_support = 7;
183 nondove_armhole_wall = 3.2;
184 nondove_armhole_slop = 0.5;
185 nondove_armhole_slop_x = 0.5;
187 nondove_armbase = nondove_armhole_x + nondove_armhole_hole/2 +
188 nondove_armhole_support;
189 echo(nondove_armbase);
191 include <doveclip.scad>
192 include <cliphook.scad>
193 include <filamentteeth.scad>
194 include <axlepin.scad>
196 channelwidth = prongthick + channelslop;
197 channeldepth = prongwidth + ratchettoothheight;
198 totalwidth = armendwallthick*2 + channelwidth;
199 totalheight = channeldepth + armendbasethick;
200 stalkwidth = prongwidth + prongstalkxwidth;
202 module ArmEnd(length=armend_length){ ////toplevel
204 translate([ratchettoothsmoothr, channelwidth/2, -armendbasethick]) {
206 DoveClipPairBase(h=doveclipheight);
210 translate([1, -armendwallthick, -armendbasethick])
212 cube([nondove_armbase+1, totalwidth, totalheight]);
213 translate([-nondove_armbase + nondove_armhole_x,
214 -armendwallthick + totalwidth/2,
215 -armendbasethick -1])
216 cylinder(r= nondove_armhole_hole/2, h=totalheight+2, $fn=10);
221 translate([0, -armendwallthick, -armendbasethick])
222 cube([length, totalwidth, totalheight]);
223 translate([-1, 0, 0])
224 cube([length+1 - ratchettooth, channelwidth, channeldepth+1]);
225 translate([-1, 0, ratchettoothheight])
226 cube([length+2, channelwidth, channeldepth+1]);
228 for (dx = [0 : ratchetstep : length - ratchetstep]) translate([dx,0,0]) {
229 translate([ratchettoothsmoothr+0.5, armendwallthick/2, 0]) minkowski(){
231 cylinder($fn=20, r=ratchettoothsmoothr, h=armendwallthick);
232 multmatrix([ [ 1, 0, ratchettoothslope, 0 ],
236 cube([ratchettooth - ratchettoothsmoothr*2,
237 channelwidth, ratchettoothheight - ratchettoothsmoothr]);
242 module FilamentCupHandle(){
243 pawlusewidth = ratchetpawl-ratchettoothsmoothr*2;
245 cube([stalklength, stalkwidth, prongthick]);
246 translate([stalklength, stalkwidth/2, 0])
247 cylinder(r=stalkwidth/2, h=prongthick, $fn=20);
248 translate([ratchettoothsmoothr, stalkwidth, 0]) {
250 cylinder($fn=20,r=ratchettoothsmoothr, h=1);
251 multmatrix([ [ 1, -ratchettoothslope, 0, 0 ],
256 ratchettoothheight - ratchettoothsmoothr,
263 module FilamentCupCup(){
264 for (my=[0,1]) mirror([0,my,0]) {
265 translate([0, cupwidth/2, 0])
266 cube([cupheight + prongwidth, prongwidth, prongthick]);
270 module FilamentCup() { ////toplevel
274 dy = cupwidth/2 + gapy + overclipcupgap;
275 baselen = dy+cupwidth/2;
277 translate([0, dy, 0])
279 cube([prongwidth, baselen+1, prongthick]);
281 translate([cupstrong_dx, prongwidth, 0]) {
282 cube([prongwidth, baselen-prongwidth, prongthick]);
283 for (y = [0, .33, .67, 1])
284 translate([0, (baselen - prongwidth) * y, 0])
285 cube([-cupstrong_dx + 1, prongwidth, prongthick]);
287 if (cupstrong_dx != 0) {
289 translate([-prongwidth*.55, -prongwidth*2.1, 0])
290 cube([prongwidth*(2.65), prongwidth*4.2, prongthick]);
293 translate([0, -0.2, 0])
294 cube([prongribwidth, baselen, prongthick + prongribheight]);
296 if (prongribheight > 0) {
297 translate([-prongwidth, baselen, 0])
298 cube([cupheight/2, prongwidth + prongribheight, prongribwidth]);
301 midrad = cupwidth/2 + prongwidth/2;
303 propshift = stalklength - overclipdepth - prongthick + propxshift;
304 proptaken = propshift;
305 echo(midrad, propshift, proptaken);
307 translate([propshift, -1, 0]) {
308 // something is wrong with the y calculation
313 for (y = [overclipcupgap, overclipcupgap+overclipcupnextgap]) {
314 translate([cupstrong_dx, y + prongwidth, 0])
315 rotate([0,0, 102 + fdia])
316 FilamentTeeth(fdia=fdia, h=teethh);
318 for (x = [-0.3, -1.3]) {
319 translate([cupheight + overclipcupnextgap*x, baselen + prongwidth, 0])
320 rotate([0,0, 12 + fdia])
321 FilamentTeeth(fdia=fdia, h=teethh);
325 module CupSecuringClipSolid(w,d,h1,h2){
326 rotate([0,-90,0]) translate([0,-h1/2,-w/2]) linear_extrude(height=w) {
327 polygon(points=[[0,0], [d,0], [d,h2], [0,h1]]);
331 module CupSecuringClipSolidSmooth(xrad=0, xdepth=0){
332 hbase = totalheight + prongstalkxwidth - overcliproundr*2;
334 CupSecuringClipSolid(w=totalwidth,
335 d=overclipdepth + xdepth,
336 h1=hbase - overclipsmaller,
337 h2=hbase + overclipbigger);
338 cylinder($fn=20, h=0.01, r=overcliproundr+xrad);
342 module CupSecuringClip(){ ////toplevel
343 wingswidth = wingspoke*2 + overclipthick*2 + overcliproundr*2 + totalwidth;
346 CupSecuringClipSolidSmooth(xrad=overclipthick, xdepth=0);
347 translate([-wingswidth/2, -wingsize/2, 0])
348 cube([wingswidth, wingsize, wingthick]);
349 translate([-wingsize/2, -wingswidth/2, 0])
350 cube([wingsize, wingswidth, wingthick]);
352 translate([0,0,-0.1])
353 CupSecuringClipSolidSmooth(xrad=0, xdepth=0.2);
357 module ArmDoveClipPin(){ ////toplevel
358 DoveClipPin(h=doveclipheight);
361 module TowerDoveClipPin(){ ////toplevel
362 DoveClipPin(h=towercliph/2);
365 module Hub(){ ////toplevel
366 axlerad = hubaxlerad + slop;
367 xmin = axlerad+hublwidth/2;
368 xmax = hubbigrad-hublwidth/2;
369 hole = hubeffrad - hubbigrad - DoveClip_depth() - hublwidth*2;
370 holewidth = DoveClipPairSane_width() - hubstemwidth*2;
371 nondove_allwidth = nondove_armhole_wall*2 + totalwidth;
375 cylinder($fn=60, h=hublthick, r=hubbigrad);
377 cylinder($fn=30, h=hublthick+2, r=(hubbigrad-hublwidth));
379 cylinder(h=hubaxlelen, r=axlerad+hublwidth);
380 for (ang=[0 : 360/num_arms : 359])
384 translate([hubeffrad,0,0])
385 DoveClipPairSane(h=doveclipheight,
386 baseextend = (hubeffrad - DoveClip_depth()
387 - hubbigrad + hublwidth));
388 if (hole>hublwidth && holewidth > 2) {
389 translate([hubbigrad + hublwidth, -holewidth/2, -1])
390 cube([hole, holewidth, hublthick+2]);
398 cube([hubeffrad + nondove_armhole_x
399 + nondove_armhole_hole/2 + nondove_armhole_support,
401 nondove_armhole_wall + totalheight]);
402 translate([hubeffrad - nondove_armhole_slop_x,
404 + nondove_armhole_wall - nondove_armhole_slop,
405 nondove_armhole_wall])
406 cube([nondove_armhole_x + 50,
407 totalwidth + nondove_armhole_slop*2,
409 translate([hubeffrad + nondove_armhole_x, 0, -20])
410 cylinder(r= nondove_armhole_hole/2, h=50, $fn=10);
414 for (ang = [0 : 180/num_arms : 359])
415 rotate([0,0,ang]) rotate([90,0,0]) {
416 translate([0,0,-hublwidth/2])
417 linear_extrude(height=hublwidth)
418 polygon([[xmin,0.05], [xmax,0.05],
419 [xmax,hublthick-0.2], [xmin, hubaxlelen-0.2]]);
422 translate([0,0,-1]) cylinder($fn=60, h=hubaxlelen+2, r=axlerad);
426 module ArmExtender(){ ////toplevel
427 DoveClipExtender(length=exteffrad-hubeffrad,
432 module FsAxlePin(){ ////toplevel
433 AxlePin(hubaxlerad, washerrad*2, axlepinrad, axlepintabrad, slop);
436 module Axle(){ ////toplevel
437 pillarswidth = DoveClipPairSane_width(towerclipcount);
439 rotate([0,0, -( axleaxlefudgebend + atan(slop/hubaxlelen) ) ])
440 translate([-axlehorizoffset, -axlevertheight, 0]) {
441 rotate([0,0,-axletowerfudgebend])
443 DoveClipPairSane(h=towercliph, count=towerclipcount, baseextend=3);
444 translate([0, DoveClip_depth(), 0])
446 ExtenderPillars(axlevertheight - DoveClip_depth(),
447 pillarswidth, towercliph,
448 pillarw=towerpillarw);
451 axleclearlen = hubaxlelen + slop*4 + washerthick*2 + axlepadlen;
452 axlerad = hubaxlerad-slop;
453 bump = axlerad * 0.2;
454 shift = axlerad-bump;
458 translate([0, 0, shift]) {
461 translate([-1, 0, 0])
465 h = 1 + axleclearlen + axlepinrad*2 + 2);
466 mirror([1,0,0]) rotate([0,90,0])
467 cylinder(r = axlerad*1.75, h = 3);
470 translate([axlehorizoffset - pillarswidth/2, 0, 0])
473 r = towercliph - shift,
475 translate([-50, -joinbelowallow, -50])
476 cube([100, joinbelowallow+50, 100]);
480 translate([axleclearlen + axlepinrad/2, 0, -25])
481 cylinder(r = axlepinrad + slop, h=50);
484 translate([-50,-50,0]) cube([100,100,100]);
488 module washer(thick){
489 Washer(hubaxlerad, washerrad, thick, slop);
492 module AxleWasher(){ ////toplevel
493 washer(thick=washerthick);
496 module AxleThinWasher(){ ////toplevel
497 washer(thick=washerthinthick);
500 module AxleVeryThinWasher(){ ////toplevel
501 washer(thick=washerverythinthick);
504 module AxleFrictionWasher(){ ////toplevel
506 cylinder(h=washerthick, r=washerrad);
507 translate([0,0,-1]) cylinder(h=washerthick+2, r=hubaxlerad+slop);
510 frarmw = frictionwasherarmwidth;
511 frarmpawlr = hublwidth;
512 frarmpawlpush = slop*4 + frictionwasherextrapush;
513 for (ang=[0,180]) rotate([0,0,ang]) {
514 translate([washerrad-1, -frarmw/2, 0])
515 cube([frarmr - washerrad + 1, frarmw, washerthick]);
517 translate([frarmr - frarmpawlr, -50, 0])
518 cube([frarmpawlr, 100, 50]);
520 cylinder(h = 50, r = frarmpawlpush, $fn=36);
525 module TowerExtender(){ ////toplevel
526 l = totalheightfromtower - axlevertheight;
527 echo("TowerExtender",l);
528 DoveClipExtender(length = l,
529 ha = towercliph, hb = towercliph,
530 counta = towerclipcount, countb = towerclipcount,
531 pillarw = towerpillarw);
534 module FilamentCupPair(){ ////toplevel
536 translate([cupheight + prongthick*3,
539 rotate([0,0,180]) FilamentCup();
542 //----- storarm -----
545 storarm_hookheight = 5;
547 storarm_axleslop = 4;
550 storarm_base_h = 100;
552 storarm_base_mind = 2;
554 storarm_cope_hubaxle_mk1 = true;
556 storarm_screw_hole = 4;
557 storarm_screw_hole_slop = 0.5;
558 storarm_besides_hole = 4;
560 storarm_under_hole = 5;
561 storarm_screw_hole_head = 8.8;
562 storarm_screw_hole_head_slop = 1.5;
566 storarm_axlerad = hubaxlerad - storarm_axleslop;
567 storarm_mainlen = hubaxlelen*2 + storarm_axleslop
568 + (storarm_cope_hubaxle_mk1 ? 10 : 0);
569 storarm_totlen = storarm_mainlen + storarm_hooklen;
571 storarm_mid_off_y = storarm_axlerad;
573 storarm_base_off_y = storarm_mid_off_y + storarm_base_h/2;
575 module StorageArmDiagPartSide(xmin, xmax){
577 yuse = storarm_thick/2;
580 translate([xmin-1, -storarm_axlerad, storarm_thick/2])
582 cylinder(r=storarm_axlerad, h=xsz+2, $fn=60);
583 translate([xmin, -yuse, 0])
584 cube([xsz, yuse, storarm_thick]);
588 module StorageArmDiagPart(xmin, xmax, shear, adjbot){
590 StorageArmDiagPartSide(xmin,xmax);
592 multmatrix([[1,0,0,0],
596 translate([0, -storarm_axlerad*2 + adjbot, 0])
598 StorageArmDiagPartSide(xmin,xmax);
602 module StorageArmBaseTemplate(){
603 square([storarm_base_w, storarm_base_h]);
606 module StorageArmAtMountingHoles(){
607 bes = storarm_besides_hole + storarm_screw_hole;
610 x1 = storarm_base_w-bes;
611 y1 = storarm_base_h - bes;
618 translate([pos[0] - storarm_base_w,
619 pos[1] - storarm_base_off_y, -storarm_base_d])
624 module StorageArmRight(){ ////toplevel
625 shear = storarm_hookheight / (storarm_mainlen/2);
627 StorageArmDiagPart(-1, storarm_mainlen/2+1, shear, 0);
628 StorageArmDiagPart(storarm_mainlen/2-1, storarm_mainlen+1, shear/2,
629 storarm_hookheight/2);
631 translate([0, storarm_hookheight, 0])
632 StorageArmDiagPart(storarm_mainlen, storarm_totlen,
633 shear/2, -storarm_hookheight/2);
638 translate([-storarm_base_d, -storarm_base_off_y, storarm_base_w])
640 linear_extrude(height=storarm_base_mind)
641 StorageArmBaseTemplate();
642 StorageArmDiagPart(-1, 0, shear, 0);
644 StorageArmAtMountingHoles(){
645 cylinder(r= storarm_screw_hole_head/2,
649 StorageArmAtMountingHoles(){
651 cylinder(r= (storarm_screw_hole + storarm_screw_hole_slop)/2 ,
653 translate([0,0,storarm_under_hole])
654 cylinder(r= (storarm_screw_hole_head + storarm_screw_hole_head_slop)/2,
660 module StorageArmLeft(){ ////toplevel
661 mirror([1,0,0]) StorageArmRight();
664 module StorArmHoleTest(){ ////toplevel
665 sz = storarm_screw_hole_head + storarm_besides_hole*2;
668 translate([-50, -storarm_base_off_y, -1])
669 cube([100, sz, sz+1]);
675 translate([-hubeffrad-30,50,0]) Hub();
677 translate([0,50,0]) FilamentCup();
689 //AxleFrictionWasher();