// -*- C -*- // todo // various registration marks // protrustions at ends at strap width and middle // grooves on top face at 1/4,1/2,3/4 length and 1/2 width strap_thick = 3; strap_width = 26.75 + 0.7; jig_interval = 25; edgewall_width = 3; crewpunch_slop = 0.3; main_slop = 0.25; holder_min_wall = 2; holder_attach_near_wall = 5; holder_attach_xsz = 5; holder_ctie_width = 4.0 + 0.5; holder_ctie_thick = 3.0 + 0.5; holder_attach_walls = 3; holder_attach_roof = 2.5; holder_corner_round = 2.0; punch_travel = 8; // from careful measurement crewpunch_shape = [[ 6, [0.6, 6.0], [1.6, 12.3] ], [ 8, [1.1, 6.2], [1.9, 12.5] ], [ 10, [1.6, 6.5], [2.1, 12.8] ], [ 12, [1.8, 6.6], [2.3, 12.7] ], [ 14, [2.1, 6.8], [2.6, 13.0] ], [ 16, [2.4, 6.9], [2.7, 13.2] ], [ 18, [2.5, 7.0], [2.9, 13.3] ], [ 22, [3.1, 7.1], [3.2, 13.4] ], [ 26, [3.3, 7.2], [3.5, 13.6] ], ]; crewpunch_shaft_max_y = 7.5; crewpunch_systematic_size_error = +0.36; crewpunch_smallest_shape = crewpunch_shape[0]; crewpunch_biggest_shape = crewpunch_shape[len(crewpunch_shape)-1]; crewpunch_skew_angle = 3.5; //degrees crewpunch_skew_yoff = +1.1; //mm // computed punch_dx = 0.5 * (-crewpunch_biggest_shape[2][0] +crewpunch_biggest_shape[2][1]); punch_dy = 0.5 * (+crewpunch_biggest_shape[1][1] -crewpunch_biggest_shape[1][0]) + crewpunch_skew_yoff; attach_ysz = holder_attach_walls*2 + holder_ctie_width; holder_block_zsz = crewpunch_biggest_shape[0] - crewpunch_smallest_shape[0]; holder_xsz = crewpunch_biggest_shape[2][0] + crewpunch_biggest_shape[2][1] + holder_min_wall*2; holder_skewangle_yextra = holder_xsz/2 * sin(abs(crewpunch_skew_angle)); holder_max_y = punch_dy + crewpunch_biggest_shape[1][0] + holder_min_wall + crewpunch_systematic_size_error + holder_skewangle_yextra; holder_attach_max_y = punch_dy - max(crewpunch_biggest_shape[1][1], crewpunch_shaft_max_y) - crewpunch_systematic_size_error - holder_skewangle_yextra; holder_block_min_y = punch_dy - crewpunch_biggest_shape[1][1] - holder_attach_near_wall + - crewpunch_systematic_size_error - holder_skewangle_yextra; holder_all_min_y = holder_attach_max_y - attach_ysz; jig_max_y = max(holder_max_y + main_slop, strap_width/2) + edgewall_width; jig_min_y = min(holder_all_min_y - main_slop, -strap_width/2) - edgewall_width; jig_main_zsz = holder_block_zsz + punch_travel; // common stuff include // objects module CrewPunch(){ ourslop = crewpunch_slop - crewpunch_systematic_size_error; hull(){ for(layer=crewpunch_shape){ translate([0,0, layer[0]]){ for(xind=[0,1]) //translate([xind?0:1,0,0]) for(yind=[0,1]) //translate([0,yind?0.5:0,0]) mirror([xind?1:0,0,0]) mirror([0,yind?0:1,0]){ translate([-0.1,-0.1,-0.1]) cube([0.1 + layer[2][xind] + ourslop, 0.1 + layer[1][1-yind] + ourslop, 0.2]); } } } } } module MaybeRoundedCube(sizes, roundedness){ if (roundedness > 0) { translate([roundedness, roundedness, 0]){ minkowski(){ cube([sizes[0] - roundedness*2, sizes[1] - roundedness*2, sizes[2]]); cylinder(h=0.05, r=roundedness, $fn=20); } } } else { cube(sizes); } } module PunchHolder(cutouts=true){ roundedness = cutouts ? holder_corner_round : 0; difference(){ translate([-holder_xsz/2, holder_block_min_y, 0]) MaybeRoundedCube([holder_xsz, holder_max_y - holder_block_min_y, holder_block_zsz], roundedness); if (cutouts) rotate([0,0,-crewpunch_skew_angle]) translate([punch_dx, punch_dy, -crewpunch_smallest_shape[0]]) CrewPunch(); } difference(){ translate([-holder_attach_xsz/2, holder_all_min_y, 0]) MaybeRoundedCube([holder_attach_xsz, attach_ysz, holder_block_zsz + punch_travel + holder_ctie_thick + holder_attach_roof + 1], roundedness); if (cutouts) translate([-30, holder_all_min_y + holder_attach_walls, holder_block_zsz + punch_travel]) cube([60, holder_ctie_width, holder_ctie_thick]); } } module OneJigCutout(){ minkowski(){ cube([main_slop*2, main_slop*2, 50], center=true); PunchHolder(false); } } module JigT(){ ////toplevel JigPrint(); } module PunchHolderT(){ ////toplevel PunchHolder(true); } module Demo(){ ////toplevel %PunchHolder(); Jig(); } module Kit(){ ////toplevel JigT(); rotate([0,0,-45]){ translate([(jig_iters-1)*jig_interval/2, jig_min_y - holder_max_y - 5, 0]) PunchHolder(); } } //CrewPunch(); //PunchHolder(); //PunchHolder(false); //OneJig(); //Jig(); Demo(); //JigT(); //RegistrationProtrusion(); //PunchHolderT(); //Kit();