3 // Filament spool for filament coils as supplied by Faberdashery
5 // Each spool is a hub with 3 or 4 arms. Each arm has a cup for
6 // holding the filament. The effective diameter can be adjusted by
7 // setting the cup into a different seat in the arm. The cups are
8 // held on with simple clips, so the filement coil can easily be
9 // removed and replaced.
11 // This file (and its includes) can generate:
13 // - Heavy duty 4-armed spool suitable for holding a 100m
14 // Faberdashery coil on the spool arm of a Lulzbot TAZ-5.
19 // And print following parts
22 // FilamentCup x 4 (or FilamentCupPair x 2)
23 // CupSecuringClup x 4
25 // You will also need 4 x M4 machine screws and nuts
27 // - Light duty 3-armed spool suitable for up to around 30m
28 // of Faberdashery 2.85mm PLA.
33 // And print following parts
36 // FilamentCup x 3 (or FilamentCup + FilamentCupPair)
37 // CupSecuringClup x 3
38 // TowerDoveClipPin x 6
40 // When assembling, insert one TowerDoveClipPin from each side,
41 // joining each ArmEnd to the Hub with two TowerDoveClipPins.
42 // Modest force with pliers is good to seat them properly.
44 // (note that the light duty and heavy duty CupSecuringClips
45 // are slightly different)
47 // For the above, I generally used the Cura `Standard' PLA profile.
49 // - Storage arm suitable for screwing to walls, bookshelves,
50 // etc. (requires non-countersunk M4 screws); will hold two
51 // heavy duty spools each with a 100m coil.
56 // And print one of these, according to taste
60 // NB that the `light duty' version of this is shorter and
61 // will only take two `light duty' spools.
63 // For the above, I used the Cura `High detail' PLA profile because
64 // I wanted it pretty, but the `Standard' profile should do fine.
66 // - Spool (in many parts) for handing 1.75mm filament, printable
67 // on, and with parts for mounting on, a Reprappro Huxley.
71 lightduty=false; // or true
77 function selsz(sm,lt,lg) = fdia < 2 ? sm : lightduty ? lt : lg;
78 function usedove() = selsz(true,true,false);
80 num_arms = selsz(3,3,4);
82 channelslop=selsz(slop,0.75,slop);
85 hubeffrad = selsz(30, 82, 40);
86 hubbigrad = selsz(20, 38, 38);
87 hublwidth = selsz(3, 2.5, 4);
90 hubaxlerad = selsz(5, 28/2, 28/2);
91 totalheightfromtower = 240;
92 axletowerfudgebend = 0;
93 axleaxlefudgebend = 3;
98 prongthick=selsz(5,4,5);
99 prongwidth=selsz(5,4,5);
101 prongribheight=selsz(0,0,4);
104 ratchettoothheight=5;
105 ratchettoothsmoothr=1;
106 ratchettoothslope=0.75;
108 cupwidth=selsz(40,25,50);
109 cupheight=selsz(55,25,55);
111 cupstrong_dx=selsz(0,0,-10);
122 stalklength=selsz(35,25,55);
127 overclipcupnextgap=selsz(20,15,20);
129 hubaxlelen = selsz(25, 62.5, 77.5);
132 overclipsmaller=-2.5;
139 armendwallthick=selsz(2.5, 1.8, 2.5);
140 armendbasethick=selsz(1.2, 1.2, 1.2);
142 axlehorizoffset = 12.5;
143 axlevertheight = 100;
152 washerthinthick = 0.8;
153 washerverythinthick = 0.4;
154 washerrad = hubaxlerad + 7.5;
155 frictionwasherarmwidth = 3;
156 frictionwasherextrapush = 1.0;
158 ratchetpawl=ratchetstep-ratchettooth-bigslop*2;
160 nondove_armhole_x = 32;
161 nondove_armhole_hole = 4 + 0.8;
162 nondove_armhole_support = 7;
163 nondove_armhole_wall = 3.2;
164 nondove_armhole_slop = 0.5;
165 nondove_armhole_slop_x = 0.5;
167 nondove_armbase = nondove_armhole_x + nondove_armhole_hole/2 +
168 nondove_armhole_support;
169 echo(nondove_armbase);
171 include <doveclip.scad>
172 include <cliphook.scad>
173 include <filamentteeth.scad>
174 include <axlepin.scad>
176 channelwidth = prongthick + channelslop;
177 channeldepth = prongwidth + ratchettoothheight;
178 totalwidth = armendwallthick*2 + channelwidth;
179 totalheight = channeldepth + armendbasethick;
180 stalkwidth = prongwidth + prongstalkxwidth;
182 module ArmEnd(length=armend_length){ ////toplevel
184 translate([ratchettoothsmoothr, channelwidth/2, -armendbasethick]) {
186 DoveClipPairBase(h=doveclipheight);
190 translate([1, -armendwallthick, -armendbasethick])
192 cube([nondove_armbase+1, totalwidth, totalheight]);
193 translate([-nondove_armbase + nondove_armhole_x,
194 -armendwallthick + totalwidth/2,
195 -armendbasethick -1])
196 cylinder(r= nondove_armhole_hole/2, h=totalheight+2, $fn=10);
201 translate([0, -armendwallthick, -armendbasethick])
202 cube([length, totalwidth, totalheight]);
203 translate([-1, 0, 0])
204 cube([length+1 - ratchettooth, channelwidth, channeldepth+1]);
205 translate([-1, 0, ratchettoothheight])
206 cube([length+2, channelwidth, channeldepth+1]);
208 for (dx = [0 : ratchetstep : length - ratchetstep]) translate([dx,0,0]) {
209 translate([ratchettoothsmoothr+0.5, armendwallthick/2, 0]) minkowski(){
211 cylinder($fn=20, r=ratchettoothsmoothr, h=armendwallthick);
212 multmatrix([ [ 1, 0, ratchettoothslope, 0 ],
216 cube([ratchettooth - ratchettoothsmoothr*2,
217 channelwidth, ratchettoothheight - ratchettoothsmoothr]);
222 module FilamentCupHandle(){
223 pawlusewidth = ratchetpawl-ratchettoothsmoothr*2;
225 cube([stalklength, stalkwidth, prongthick]);
226 translate([stalklength, stalkwidth/2, 0])
227 cylinder(r=stalkwidth/2, h=prongthick, $fn=20);
228 translate([ratchettoothsmoothr, stalkwidth, 0]) {
230 cylinder($fn=20,r=ratchettoothsmoothr, h=1);
231 multmatrix([ [ 1, -ratchettoothslope, 0, 0 ],
236 ratchettoothheight - ratchettoothsmoothr,
243 module FilamentCupCup(){
244 for (my=[0,1]) mirror([0,my,0]) {
245 translate([0, cupwidth/2, 0])
246 cube([cupheight + prongwidth, prongwidth, prongthick]);
250 module FilamentCup() { ////toplevel
254 dy = cupwidth/2 + gapy + overclipcupgap;
255 baselen = dy+cupwidth/2;
257 translate([0, dy, 0])
259 cube([prongwidth, baselen+1, prongthick]);
261 translate([cupstrong_dx, prongwidth, 0]) {
262 cube([prongwidth, baselen-prongwidth, prongthick]);
263 for (y = [0, .33, .67, 1])
264 translate([0, (baselen - prongwidth) * y, 0])
265 cube([-cupstrong_dx + 1, prongwidth, prongthick]);
267 if (cupstrong_dx != 0) {
269 translate([-prongwidth*.55, -prongwidth*2.1, 0])
270 cube([prongwidth*(2.65), prongwidth*4.2, prongthick]);
273 translate([0, -0.2, 0])
274 cube([prongribwidth, baselen, prongthick + prongribheight]);
276 if (prongribheight > 0) {
277 translate([-prongwidth, baselen, 0])
278 cube([cupheight/2, prongwidth + prongribheight, prongribwidth]);
281 midrad = cupwidth/2 + prongwidth/2;
283 propshift = stalklength - overclipdepth - prongthick + propxshift;
284 proptaken = propshift;
285 echo(midrad, propshift, proptaken);
287 translate([propshift, -1, 0]) {
288 // something is wrong with the y calculation
293 for (y = [overclipcupgap, overclipcupgap+overclipcupnextgap]) {
294 translate([cupstrong_dx, y + prongwidth, 0])
295 rotate([0,0, 102 + fdia])
296 FilamentTeeth(fdia=fdia, h=teethh);
298 for (x = [-0.3, -1.3]) {
299 translate([cupheight + overclipcupnextgap*x, baselen + prongwidth, 0])
300 rotate([0,0, 12 + fdia])
301 FilamentTeeth(fdia=fdia, h=teethh);
305 module CupSecuringClipSolid(w,d,h1,h2){
306 rotate([0,-90,0]) translate([0,-h1/2,-w/2]) linear_extrude(height=w) {
307 polygon(points=[[0,0], [d,0], [d,h2], [0,h1]]);
311 module CupSecuringClipSolidSmooth(xrad=0, xdepth=0){
312 hbase = totalheight + prongstalkxwidth - overcliproundr*2;
314 CupSecuringClipSolid(w=totalwidth,
315 d=overclipdepth + xdepth,
316 h1=hbase - overclipsmaller,
317 h2=hbase + overclipbigger);
318 cylinder($fn=20, h=0.01, r=overcliproundr+xrad);
322 module CupSecuringClip(){ ////toplevel
323 wingswidth = wingspoke*2 + overclipthick*2 + overcliproundr*2 + totalwidth;
326 CupSecuringClipSolidSmooth(xrad=overclipthick, xdepth=0);
327 translate([-wingswidth/2, -wingsize/2, 0])
328 cube([wingswidth, wingsize, wingthick]);
329 translate([-wingsize/2, -wingswidth/2, 0])
330 cube([wingsize, wingswidth, wingthick]);
332 translate([0,0,-0.1])
333 CupSecuringClipSolidSmooth(xrad=0, xdepth=0.2);
337 module ArmDoveClipPin(){ ////toplevel
338 DoveClipPin(h=doveclipheight);
341 module TowerDoveClipPin(){ ////toplevel
342 DoveClipPin(h=towercliph/2);
345 module Hub(){ ////toplevel
346 axlerad = hubaxlerad + slop;
347 xmin = axlerad+hublwidth/2;
348 xmax = hubbigrad-hublwidth/2;
349 hole = hubeffrad - hubbigrad - DoveClip_depth() - hublwidth*2;
350 holewidth = DoveClipPairSane_width() - hubstemwidth*2;
351 nondove_allwidth = nondove_armhole_wall*2 + totalwidth;
355 cylinder($fn=60, h=hublthick, r=hubbigrad);
357 cylinder($fn=30, h=hublthick+2, r=(hubbigrad-hublwidth));
359 cylinder(h=hubaxlelen, r=axlerad+hublwidth);
360 for (ang=[0 : 360/num_arms : 359])
364 translate([hubeffrad,0,0])
365 DoveClipPairSane(h=doveclipheight,
366 baseextend = (hubeffrad - DoveClip_depth()
367 - hubbigrad + hublwidth));
368 if (hole>hublwidth && holewidth > 2) {
369 translate([hubbigrad + hublwidth, -holewidth/2, -1])
370 cube([hole, holewidth, hublthick+2]);
378 cube([hubeffrad + nondove_armhole_x
379 + nondove_armhole_hole/2 + nondove_armhole_support,
381 nondove_armhole_wall + totalheight]);
382 translate([hubeffrad - nondove_armhole_slop_x,
384 + nondove_armhole_wall - nondove_armhole_slop,
385 nondove_armhole_wall])
386 cube([nondove_armhole_x + 50,
387 totalwidth + nondove_armhole_slop*2,
389 translate([hubeffrad + nondove_armhole_x, 0, -20])
390 cylinder(r= nondove_armhole_hole/2, h=50, $fn=10);
394 for (ang = [0 : 180/num_arms : 359])
395 rotate([0,0,ang]) rotate([90,0,0]) {
396 translate([0,0,-hublwidth/2])
397 linear_extrude(height=hublwidth)
398 polygon([[xmin,0.05], [xmax,0.05],
399 [xmax,hublthick-0.2], [xmin, hubaxlelen-0.2]]);
402 translate([0,0,-1]) cylinder($fn=60, h=hubaxlelen+2, r=axlerad);
406 module ArmExtender(){ ////toplevel
407 DoveClipExtender(length=exteffrad-hubeffrad,
412 module FsAxlePin(){ ////toplevel
413 AxlePin(hubaxlerad, washerrad*2, axlepinrad, axlepintabrad, slop);
416 module Axle(){ ////toplevel
417 pillarswidth = DoveClipPairSane_width(towerclipcount);
419 rotate([0,0, -( axleaxlefudgebend + atan(slop/hubaxlelen) ) ])
420 translate([-axlehorizoffset, -axlevertheight, 0]) {
421 rotate([0,0,-axletowerfudgebend])
423 DoveClipPairSane(h=towercliph, count=towerclipcount, baseextend=3);
424 translate([0, DoveClip_depth(), 0])
426 ExtenderPillars(axlevertheight - DoveClip_depth(),
427 pillarswidth, towercliph,
428 pillarw=towerpillarw);
431 axleclearlen = hubaxlelen + slop*4 + washerthick*2 + axlepadlen;
432 axlerad = hubaxlerad-slop;
433 bump = axlerad * 0.2;
434 shift = axlerad-bump;
438 translate([0, 0, shift]) {
441 translate([-1, 0, 0])
445 h = 1 + axleclearlen + axlepinrad*2 + 2);
446 mirror([1,0,0]) rotate([0,90,0])
447 cylinder(r = axlerad*1.75, h = 3);
450 translate([axlehorizoffset - pillarswidth/2, 0, 0])
453 r = towercliph - shift,
455 translate([-50, -joinbelowallow, -50])
456 cube([100, joinbelowallow+50, 100]);
460 translate([axleclearlen + axlepinrad/2, 0, -25])
461 cylinder(r = axlepinrad + slop, h=50);
464 translate([-50,-50,0]) cube([100,100,100]);
468 module washer(thick){
469 Washer(hubaxlerad, washerrad, thick, slop);
472 module AxleWasher(){ ////toplevel
473 washer(thick=washerthick);
476 module AxleThinWasher(){ ////toplevel
477 washer(thick=washerthinthick);
480 module AxleVeryThinWasher(){ ////toplevel
481 washer(thick=washerverythinthick);
484 module AxleFrictionWasher(){ ////toplevel
486 cylinder(h=washerthick, r=washerrad);
487 translate([0,0,-1]) cylinder(h=washerthick+2, r=hubaxlerad+slop);
490 frarmw = frictionwasherarmwidth;
491 frarmpawlr = hublwidth;
492 frarmpawlpush = slop*4 + frictionwasherextrapush;
493 for (ang=[0,180]) rotate([0,0,ang]) {
494 translate([washerrad-1, -frarmw/2, 0])
495 cube([frarmr - washerrad + 1, frarmw, washerthick]);
497 translate([frarmr - frarmpawlr, -50, 0])
498 cube([frarmpawlr, 100, 50]);
500 cylinder(h = 50, r = frarmpawlpush, $fn=36);
505 module TowerExtender(){ ////toplevel
506 l = totalheightfromtower - axlevertheight;
507 echo("TowerExtender",l);
508 DoveClipExtender(length = l,
509 ha = towercliph, hb = towercliph,
510 counta = towerclipcount, countb = towerclipcount,
511 pillarw = towerpillarw);
514 module FilamentCupPair(){ ////toplevel
516 translate([cupheight + prongthick*3,
519 rotate([0,0,180]) FilamentCup();
522 //----- storarm -----
525 storarm_hookheight = 5;
527 storarm_axleslop = 4;
530 storarm_base_h = 100;
532 storarm_base_mind = 2;
534 storarm_cope_hubaxle_mk1 = true;
536 storarm_screw_hole = 4;
537 storarm_screw_hole_slop = 0.5;
538 storarm_besides_hole = 4;
540 storarm_under_hole = 5;
541 storarm_screw_hole_head = 8.8;
542 storarm_screw_hole_head_slop = 1.5;
546 storarm_axlerad = hubaxlerad - storarm_axleslop;
547 storarm_mainlen = hubaxlelen*2 + storarm_axleslop
548 + (storarm_cope_hubaxle_mk1 ? 10 : 0);
549 storarm_totlen = storarm_mainlen + storarm_hooklen;
551 storarm_mid_off_y = storarm_axlerad;
553 storarm_base_off_y = storarm_mid_off_y + storarm_base_h/2;
555 module StorageArmDiagPartSide(xmin, xmax){
557 yuse = storarm_thick/2;
560 translate([xmin-1, -storarm_axlerad, storarm_thick/2])
562 cylinder(r=storarm_axlerad, h=xsz+2, $fn=60);
563 translate([xmin, -yuse, 0])
564 cube([xsz, yuse, storarm_thick]);
568 module StorageArmDiagPart(xmin, xmax, shear, adjbot){
570 StorageArmDiagPartSide(xmin,xmax);
572 multmatrix([[1,0,0,0],
576 translate([0, -storarm_axlerad*2 + adjbot, 0])
578 StorageArmDiagPartSide(xmin,xmax);
582 module StorageArmBaseTemplate(){
583 square([storarm_base_w, storarm_base_h]);
586 module StorageArmAtMountingHoles(){
587 bes = storarm_besides_hole + storarm_screw_hole;
590 x1 = storarm_base_w-bes;
591 y1 = storarm_base_h - bes;
598 translate([pos[0] - storarm_base_w,
599 pos[1] - storarm_base_off_y, -storarm_base_d])
604 module StorageArmRight(){ ////toplevel
605 shear = storarm_hookheight / (storarm_mainlen/2);
607 StorageArmDiagPart(-1, storarm_mainlen/2+1, shear, 0);
608 StorageArmDiagPart(storarm_mainlen/2-1, storarm_mainlen+1, shear/2,
609 storarm_hookheight/2);
611 translate([0, storarm_hookheight, 0])
612 StorageArmDiagPart(storarm_mainlen, storarm_totlen,
613 shear/2, -storarm_hookheight/2);
618 translate([-storarm_base_d, -storarm_base_off_y, storarm_base_w])
620 linear_extrude(height=storarm_base_mind)
621 StorageArmBaseTemplate();
622 StorageArmDiagPart(-1, 0, shear, 0);
624 StorageArmAtMountingHoles(){
625 cylinder(r= storarm_screw_hole_head/2,
629 StorageArmAtMountingHoles(){
631 cylinder(r= (storarm_screw_hole + storarm_screw_hole_slop)/2 ,
633 translate([0,0,storarm_under_hole])
634 cylinder(r= (storarm_screw_hole_head + storarm_screw_hole_head_slop)/2,
640 module StorageArmLeft(){ ////toplevel
641 mirror([1,0,0]) StorageArmRight();
644 module StorArmHoleTest(){ ////toplevel
645 sz = storarm_screw_hole_head + storarm_besides_hole*2;
648 translate([-50, -storarm_base_off_y, -1])
649 cube([100, sz, sz+1]);
655 translate([-hubeffrad-30,50,0]) Hub();
657 translate([0,50,0]) FilamentCup();
669 //AxleFrictionWasher();