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 // CupSecuringClip 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 // CupSecuringClip 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 // When mounting either spool on the TAZ-5 spool arm, put the `pointy'
68 // end of the hub towards the printer - ie, put put the spool on
69 // `backwards'. This ensures that the spool's arms will clear the
72 // For the above, I generally used the Cura `Standard' PLA profile.
74 // - Storage arm suitable for screwing to walls, bookshelves,
75 // etc. (requires non-countersunk M4 screws); will hold two
76 // heavy duty spools each with a 100m coil.
81 // And print one of these, according to taste
85 // NB that the `light duty' version of this is shorter and
86 // will only take two `light duty' spools.
88 // For the above, I used the Cura `High detail' PLA profile because
89 // I wanted it pretty, but the `Standard' profile should do fine.
91 // - Spool (in many parts) for handing 1.75mm filament, printable
92 // on, and with parts for mounting on, a Reprappro Huxley.
96 lightduty=false; // or true
102 function selsz(sm,lt,lg) = fdia < 2 ? sm : lightduty ? lt : lg;
103 function usedove() = selsz(true,true,false);
105 num_arms = selsz(3,3,4);
107 channelslop=selsz(slop,0.75,slop);
110 hubeffrad = selsz(30, 82, 40);
111 hubbigrad = selsz(20, 38, 38);
112 hublwidth = selsz(3, 2.5, 4);
115 hubaxlerad = selsz(5, 28/2, 28/2);
116 totalheightfromtower = 240;
117 axletowerfudgebend = 0;
118 axleaxlefudgebend = 3;
123 prongthick=selsz(5,4,5);
124 prongwidth=selsz(5,4,5);
126 prongribheight=selsz(0,0,4);
129 ratchettoothheight=5;
130 ratchettoothsmoothr=1;
131 ratchettoothslope=0.75;
133 cupwidth=selsz(40,25,50);
134 cupheight=selsz(55,25,55);
136 cupstrong_dx=selsz(0,0,-10);
147 stalklength=selsz(35,25,55);
152 overclipcupnextgap=selsz(20,15,20);
154 hubaxlelen = selsz(25, 62.5, 77.5);
157 overclipsmaller=-2.5;
164 armendwallthick=selsz(2.5, 1.8, 2.5);
165 armendbasethick=selsz(1.2, 1.2, 1.2);
167 axlehorizoffset = 12.5;
168 axlevertheight = 100;
177 washerthinthick = 0.8;
178 washerverythinthick = 0.4;
179 washerrad = hubaxlerad + 7.5;
180 frictionwasherarmwidth = 3;
181 frictionwasherextrapush = 1.0;
183 ratchetpawl=ratchetstep-ratchettooth-bigslop*2;
185 nondove_armhole_x = 32;
186 nondove_armhole_hole = 4 + 0.8;
187 nondove_armhole_support = 7;
188 nondove_armhole_wall = 3.2;
189 nondove_armhole_slop = 0.5;
190 nondove_armhole_slop_x = 0.5;
192 nondove_armbase = nondove_armhole_x + nondove_armhole_hole/2 +
193 nondove_armhole_support;
194 echo(nondove_armbase);
196 include <doveclip.scad>
197 include <cliphook.scad>
198 include <filamentteeth.scad>
199 include <axlepin.scad>
201 channelwidth = prongthick + channelslop;
202 channeldepth = prongwidth + ratchettoothheight;
203 totalwidth = armendwallthick*2 + channelwidth;
204 totalheight = channeldepth + armendbasethick;
205 stalkwidth = prongwidth + prongstalkxwidth;
207 module ArmEnd(length=armend_length){ ////toplevel
209 translate([ratchettoothsmoothr, channelwidth/2, -armendbasethick]) {
211 DoveClipPairBase(h=doveclipheight);
215 translate([1, -armendwallthick, -armendbasethick])
217 cube([nondove_armbase+1, totalwidth, totalheight]);
218 translate([-nondove_armbase + nondove_armhole_x,
219 -armendwallthick + totalwidth/2,
220 -armendbasethick -1])
221 cylinder(r= nondove_armhole_hole/2, h=totalheight+2, $fn=10);
226 translate([0, -armendwallthick, -armendbasethick])
227 cube([length, totalwidth, totalheight]);
228 translate([-1, 0, 0])
229 cube([length+1 - ratchettooth, channelwidth, channeldepth+1]);
230 translate([-1, 0, ratchettoothheight])
231 cube([length+2, channelwidth, channeldepth+1]);
233 for (dx = [0 : ratchetstep : length - ratchetstep]) translate([dx,0,0]) {
234 translate([ratchettoothsmoothr+0.5, armendwallthick/2, 0]) minkowski(){
236 cylinder($fn=20, r=ratchettoothsmoothr, h=armendwallthick);
237 multmatrix([ [ 1, 0, ratchettoothslope, 0 ],
241 cube([ratchettooth - ratchettoothsmoothr*2,
242 channelwidth, ratchettoothheight - ratchettoothsmoothr]);
247 module FilamentCupHandle(){
248 pawlusewidth = ratchetpawl-ratchettoothsmoothr*2;
250 cube([stalklength, stalkwidth, prongthick]);
251 translate([stalklength, stalkwidth/2, 0])
252 cylinder(r=stalkwidth/2, h=prongthick, $fn=20);
253 translate([ratchettoothsmoothr, stalkwidth, 0]) {
255 cylinder($fn=20,r=ratchettoothsmoothr, h=1);
256 multmatrix([ [ 1, -ratchettoothslope, 0, 0 ],
261 ratchettoothheight - ratchettoothsmoothr,
268 module FilamentCupCup(){
269 for (my=[0,1]) mirror([0,my,0]) {
270 translate([0, cupwidth/2, 0])
271 cube([cupheight + prongwidth, prongwidth, prongthick]);
275 module FilamentCup() { ////toplevel
279 dy = cupwidth/2 + gapy + overclipcupgap;
280 baselen = dy+cupwidth/2;
282 translate([0, dy, 0])
284 cube([prongwidth, baselen+1, prongthick]);
286 translate([cupstrong_dx, prongwidth, 0]) {
287 cube([prongwidth, baselen-prongwidth, prongthick]);
288 for (y = [0, .33, .67, 1])
289 translate([0, (baselen - prongwidth) * y, 0])
290 cube([-cupstrong_dx + 1, prongwidth, prongthick]);
292 if (cupstrong_dx != 0) {
294 translate([-prongwidth*.55, -prongwidth*2.1, 0])
295 cube([prongwidth*(2.65), prongwidth*4.2, prongthick]);
298 translate([0, -0.2, 0])
299 cube([prongribwidth, baselen, prongthick + prongribheight]);
301 if (prongribheight > 0) {
302 translate([-prongwidth, baselen, 0])
303 cube([cupheight/2, prongwidth + prongribheight, prongribwidth]);
306 midrad = cupwidth/2 + prongwidth/2;
308 propshift = stalklength - overclipdepth - prongthick + propxshift;
309 proptaken = propshift;
310 echo(midrad, propshift, proptaken);
312 translate([propshift, -1, 0]) {
313 // something is wrong with the y calculation
318 for (y = [overclipcupgap, overclipcupgap+overclipcupnextgap]) {
319 translate([cupstrong_dx, y + prongwidth, 0])
320 rotate([0,0, 102 + fdia])
321 FilamentTeeth(fdia=fdia, h=teethh);
323 for (x = [-0.3, -1.3]) {
324 translate([cupheight + overclipcupnextgap*x, baselen + prongwidth, 0])
325 rotate([0,0, 12 + fdia])
326 FilamentTeeth(fdia=fdia, h=teethh);
330 module CupSecuringClipSolid(w,d,h1,h2){
331 rotate([0,-90,0]) translate([0,-h1/2,-w/2]) linear_extrude(height=w) {
332 polygon(points=[[0,0], [d,0], [d,h2], [0,h1]]);
336 module CupSecuringClipSolidSmooth(xrad=0, xdepth=0){
337 hbase = totalheight + prongstalkxwidth - overcliproundr*2;
339 CupSecuringClipSolid(w=totalwidth,
340 d=overclipdepth + xdepth,
341 h1=hbase - overclipsmaller,
342 h2=hbase + overclipbigger);
343 cylinder($fn=20, h=0.01, r=overcliproundr+xrad);
347 module CupSecuringClip(){ ////toplevel
348 wingswidth = wingspoke*2 + overclipthick*2 + overcliproundr*2 + totalwidth;
351 CupSecuringClipSolidSmooth(xrad=overclipthick, xdepth=0);
352 translate([-wingswidth/2, -wingsize/2, 0])
353 cube([wingswidth, wingsize, wingthick]);
354 translate([-wingsize/2, -wingswidth/2, 0])
355 cube([wingsize, wingswidth, wingthick]);
357 translate([0,0,-0.1])
358 CupSecuringClipSolidSmooth(xrad=0, xdepth=0.2);
362 module ArmDoveClipPin(){ ////toplevel
363 DoveClipPin(h=doveclipheight);
366 module TowerDoveClipPin(){ ////toplevel
367 DoveClipPin(h=towercliph/2);
370 module Hub(){ ////toplevel
371 axlerad = hubaxlerad + slop;
372 xmin = axlerad+hublwidth/2;
373 xmax = hubbigrad-hublwidth/2;
374 hole = hubeffrad - hubbigrad - DoveClip_depth() - hublwidth*2;
375 holewidth = DoveClipPairSane_width() - hubstemwidth*2;
376 nondove_allwidth = nondove_armhole_wall*2 + totalwidth;
380 cylinder($fn=60, h=hublthick, r=hubbigrad);
382 cylinder($fn=30, h=hublthick+2, r=(hubbigrad-hublwidth));
384 cylinder(h=hubaxlelen, r=axlerad+hublwidth);
385 for (ang=[0 : 360/num_arms : 359])
389 translate([hubeffrad,0,0])
390 DoveClipPairSane(h=doveclipheight,
391 baseextend = (hubeffrad - DoveClip_depth()
392 - hubbigrad + hublwidth));
393 if (hole>hublwidth && holewidth > 2) {
394 translate([hubbigrad + hublwidth, -holewidth/2, -1])
395 cube([hole, holewidth, hublthick+2]);
403 cube([hubeffrad + nondove_armhole_x
404 + nondove_armhole_hole/2 + nondove_armhole_support,
406 nondove_armhole_wall + totalheight]);
407 translate([hubeffrad - nondove_armhole_slop_x,
409 + nondove_armhole_wall - nondove_armhole_slop,
410 nondove_armhole_wall])
411 cube([nondove_armhole_x + 50,
412 totalwidth + nondove_armhole_slop*2,
414 translate([hubeffrad + nondove_armhole_x, 0, -20])
415 cylinder(r= nondove_armhole_hole/2, h=50, $fn=10);
419 for (ang = [0 : 180/num_arms : 359])
420 rotate([0,0,ang]) rotate([90,0,0]) {
421 translate([0,0,-hublwidth/2])
422 linear_extrude(height=hublwidth)
423 polygon([[xmin,0.05], [xmax,0.05],
424 [xmax,hublthick-0.2], [xmin, hubaxlelen-0.2]]);
427 translate([0,0,-1]) cylinder($fn=60, h=hubaxlelen+2, r=axlerad);
431 module ArmExtender(){ ////toplevel
432 DoveClipExtender(length=exteffrad-hubeffrad,
437 module FsAxlePin(){ ////toplevel
438 AxlePin(hubaxlerad, washerrad*2, axlepinrad, axlepintabrad, slop);
441 module Axle(){ ////toplevel
442 pillarswidth = DoveClipPairSane_width(towerclipcount);
444 rotate([0,0, -( axleaxlefudgebend + atan(slop/hubaxlelen) ) ])
445 translate([-axlehorizoffset, -axlevertheight, 0]) {
446 rotate([0,0,-axletowerfudgebend])
448 DoveClipPairSane(h=towercliph, count=towerclipcount, baseextend=3);
449 translate([0, DoveClip_depth(), 0])
451 ExtenderPillars(axlevertheight - DoveClip_depth(),
452 pillarswidth, towercliph,
453 pillarw=towerpillarw);
456 axleclearlen = hubaxlelen + slop*4 + washerthick*2 + axlepadlen;
457 axlerad = hubaxlerad-slop;
458 bump = axlerad * 0.2;
459 shift = axlerad-bump;
463 translate([0, 0, shift]) {
466 translate([-1, 0, 0])
470 h = 1 + axleclearlen + axlepinrad*2 + 2);
471 mirror([1,0,0]) rotate([0,90,0])
472 cylinder(r = axlerad*1.75, h = 3);
475 translate([axlehorizoffset - pillarswidth/2, 0, 0])
478 r = towercliph - shift,
480 translate([-50, -joinbelowallow, -50])
481 cube([100, joinbelowallow+50, 100]);
485 translate([axleclearlen + axlepinrad/2, 0, -25])
486 cylinder(r = axlepinrad + slop, h=50);
489 translate([-50,-50,0]) cube([100,100,100]);
493 module washer(thick){
494 Washer(hubaxlerad, washerrad, thick, slop);
497 module AxleWasher(){ ////toplevel
498 washer(thick=washerthick);
501 module AxleThinWasher(){ ////toplevel
502 washer(thick=washerthinthick);
505 module AxleVeryThinWasher(){ ////toplevel
506 washer(thick=washerverythinthick);
509 module AxleFrictionWasher(){ ////toplevel
511 cylinder(h=washerthick, r=washerrad);
512 translate([0,0,-1]) cylinder(h=washerthick+2, r=hubaxlerad+slop);
515 frarmw = frictionwasherarmwidth;
516 frarmpawlr = hublwidth;
517 frarmpawlpush = slop*4 + frictionwasherextrapush;
518 for (ang=[0,180]) rotate([0,0,ang]) {
519 translate([washerrad-1, -frarmw/2, 0])
520 cube([frarmr - washerrad + 1, frarmw, washerthick]);
522 translate([frarmr - frarmpawlr, -50, 0])
523 cube([frarmpawlr, 100, 50]);
525 cylinder(h = 50, r = frarmpawlpush, $fn=36);
530 module TowerExtender(){ ////toplevel
531 l = totalheightfromtower - axlevertheight;
532 echo("TowerExtender",l);
533 DoveClipExtender(length = l,
534 ha = towercliph, hb = towercliph,
535 counta = towerclipcount, countb = towerclipcount,
536 pillarw = towerpillarw);
539 module FilamentCupPair(){ ////toplevel
541 translate([cupheight + prongthick*3,
544 rotate([0,0,180]) FilamentCup();
547 //----- storarm -----
550 storarm_hookheight = 5;
552 storarm_axleslop = 4;
555 storarm_base_h = 100;
557 storarm_base_mind = 2;
559 storarm_cope_hubaxle_mk1 = true;
561 storarm_screw_hole = 4;
562 storarm_screw_hole_slop = 0.5;
563 storarm_besides_hole = 4;
565 storarm_under_hole = 5;
566 storarm_screw_hole_head = 8.8;
567 storarm_screw_hole_head_slop = 1.5;
571 storarm_axlerad = hubaxlerad - storarm_axleslop;
572 storarm_mainlen = hubaxlelen*2 + storarm_axleslop
573 + (storarm_cope_hubaxle_mk1 ? 10 : 0);
574 storarm_totlen = storarm_mainlen + storarm_hooklen;
576 storarm_mid_off_y = storarm_axlerad;
578 storarm_base_off_y = storarm_mid_off_y + storarm_base_h/2;
580 module StorageArmDiagPartSide(xmin, xmax){
582 yuse = storarm_thick/2;
585 translate([xmin-1, -storarm_axlerad, storarm_thick/2])
587 cylinder(r=storarm_axlerad, h=xsz+2, $fn=60);
588 translate([xmin, -yuse, 0])
589 cube([xsz, yuse, storarm_thick]);
593 module StorageArmDiagPart(xmin, xmax, shear, adjbot){
595 StorageArmDiagPartSide(xmin,xmax);
597 multmatrix([[1,0,0,0],
601 translate([0, -storarm_axlerad*2 + adjbot, 0])
603 StorageArmDiagPartSide(xmin,xmax);
607 module StorageArmBaseTemplate(){
608 square([storarm_base_w, storarm_base_h]);
611 module StorageArmAtMountingHoles(){
612 bes = storarm_besides_hole + storarm_screw_hole;
615 x1 = storarm_base_w-bes;
616 y1 = storarm_base_h - bes;
623 translate([pos[0] - storarm_base_w,
624 pos[1] - storarm_base_off_y, -storarm_base_d])
629 module StorageArmRight(){ ////toplevel
630 shear = storarm_hookheight / (storarm_mainlen/2);
632 StorageArmDiagPart(-1, storarm_mainlen/2+1, shear, 0);
633 StorageArmDiagPart(storarm_mainlen/2-1, storarm_mainlen+1, shear/2,
634 storarm_hookheight/2);
636 translate([0, storarm_hookheight, 0])
637 StorageArmDiagPart(storarm_mainlen, storarm_totlen,
638 shear/2, -storarm_hookheight/2);
643 translate([-storarm_base_d, -storarm_base_off_y, storarm_base_w])
645 linear_extrude(height=storarm_base_mind)
646 StorageArmBaseTemplate();
647 StorageArmDiagPart(-1, 0, shear, 0);
649 StorageArmAtMountingHoles(){
650 cylinder(r= storarm_screw_hole_head/2,
654 StorageArmAtMountingHoles(){
656 cylinder(r= (storarm_screw_hole + storarm_screw_hole_slop)/2 ,
658 translate([0,0,storarm_under_hole])
659 cylinder(r= (storarm_screw_hole_head + storarm_screw_hole_head_slop)/2,
665 module StorageArmLeft(){ ////toplevel
666 mirror([1,0,0]) StorageArmRight();
669 module StorArmHoleTest(){ ////toplevel
670 sz = storarm_screw_hole_head + storarm_besides_hole*2;
673 translate([-50, -storarm_base_off_y, -1])
674 cube([100, sz, sz+1]);
679 //----- filament guide spacer -----
682 guide_armwidth = 10.2;
683 guide_armcorelen = 15.3;
685 guidefilclip_outerdia = 22.8;
687 guidespacer_armslop = 0.75;
688 guidespacer_armlenslop = 0.75;
690 guidespacer_prongprotrude = 4;
691 guidespacer_thick = 1.6;
695 guidespacer_armdia = guide_armdia + guidespacer_armslop;
696 guidespacer_armwidth = guide_armwidth + guidespacer_armslop;
697 guidespacer_len = guide_armcorelen + guidespacer_armlenslop;
699 guidespacer_wingheight = (guidefilclip_outerdia - guidespacer_armdia)/2;
701 module FilamentGuideArmTemplate(extra=0){
703 circle(r= (guidespacer_armdia/2) + extra);
704 square(center=true, [guidespacer_armwidth+extra*2,
705 guidespacer_armdia + extra*2 + 10]);
709 module FilamentGuideSpacerInnerTemplate(){
710 FilamentGuideArmTemplate();
711 translate([0, -guidespacer_armdia/2])
712 square(center=true, [guidespacer_armwidth - guidespacer_prongprotrude,
713 guidespacer_armdia]);
716 module FilamentGuideSpacer(){ ////toplevel
719 linear_extrude(height= guidespacer_len)
720 FilamentGuideArmTemplate(extra= guidespacer_thick);
721 for (angle=[26, 60]) {
724 rotate([0,0,angle]) {
726 for (t=[[0, guidespacer_wingheight],
727 [guidespacer_len-1, -guidespacer_wingheight]])
728 translate([0,0, t[0] + 0.5])
729 cube([guidespacer_thick, guidespacer_armdia + t[1]*2,
739 linear_extrude(height= guidespacer_len+5)
740 FilamentGuideSpacerInnerTemplate();
745 //----- replacement filament guide arm for TAZ-5 -----
747 guidearm_armslop = 0.25;
748 guidearm_armlenslop = 0.25;
750 guidearm_hookprotr = 4;
751 guidearm_hookprotrflat = 1;
752 guidearm_hookslope = 0.3;
754 guidearm_totallen = 60;
756 guidearm_screwplatesz = 12;
757 guidearm_screwplateth = 4;
758 guidearm_screwhole = 4 + 0.5;
760 guidearm_bendlen = 50;
761 guidearm_bendslot = 5;
763 guidearm_stopthick = 4;
767 guidearm_armdia = guide_armdia - guidearm_armslop;
768 guidearm_armwidth = guide_armwidth - guidearm_armslop;
769 guidearm_armcorelen = guide_armcorelen + guidearm_armlenslop;
771 guidearm_base_z0 = -(guidearm_totallen - guidearm_armcorelen);
773 guidearm_realbendlen = min(guidearm_bendlen,
774 guidearm_totallen - guidearm_screwplateth - 0.1);
776 module FilamentGuideArmStop(h){
778 translate([ts * guidearm_hookprotr, 0,0])
779 cylinder(r=guidearm_armdia/2, h);
783 module FilamentGuideArmShaftPositive(){
784 r = guidearm_armdia/2;
786 translate([0,0, guidearm_base_z0+1])
787 cylinder(r=r, h= guidearm_totallen);
788 translate([0,0, guidearm_armcorelen]){
790 FilamentGuideArmStop(guidearm_hookprotrflat);
791 translate([0,0, guidearm_hookprotr/guidearm_hookslope])
792 cylinder(r=r, h=guidearm_hookprotrflat);
796 FilamentGuideArmStop(guidearm_stopthick);
799 module FilamentGuideArmBase(){
800 translate([0,0, guidearm_base_z0]){
802 translate([0,0, guidearm_screwplateth/2])
804 [guidearm_armdia + guidearm_screwplatesz*2,
806 guidearm_screwplateth]);
808 translate([ts * (guidearm_armdia/2 + guidearm_screwplatesz/2),
811 cylinder(r= guidearm_screwhole/2, h=40);
817 module FilamentGuideArm(){ ///toplevel
820 FilamentGuideArmShaftPositive();
821 translate([-guidearm_bendslot/2,
823 -guidearm_realbendlen + guidearm_armcorelen])
824 cube([guidearm_bendslot,
826 guidearm_realbendlen + 100]);
831 guidearm_totallen*3]);
833 FilamentGuideArmBase();
838 translate([-hubeffrad-30,50,0]) Hub();
840 translate([0,50,0]) FilamentCup();
852 //AxleFrictionWasher();
855 //FilamentGuideSpacer();
856 //FilamentGuideArm();