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
11 holder_attach_near_wall = 5;
13 holder_attach_xsz = 5;
14 holder_ctie_width = 4.0 + 0.5;
15 holder_ctie_thick = 3.0 + 0.5;
16 holder_attach_walls = 3;
17 holder_attach_roof = 2.5;
19 holder_corner_round = 2.0;
22 strap_width = 26.75 + 0.7;
30 jig_max_len = 160; // print diagonally
33 registrationgroove_width = 0.8;
34 registrationgroove_depth = 1.2;
36 registrationprotrusion_poke = 3;
37 registrationprotrusion_slope = 0.75;
41 // from careful measurement
44 [[ 6, [0.6, 6.0], [1.6, 12.3] ],
45 [ 8, [1.1, 6.2], [1.9, 12.5] ],
46 [ 10, [1.6, 6.5], [2.1, 12.8] ],
47 [ 12, [1.8, 6.6], [2.3, 12.7] ],
48 [ 14, [2.1, 6.8], [2.6, 13.0] ],
49 [ 16, [2.4, 6.9], [2.7, 13.2] ],
50 [ 18, [2.5, 7.0], [2.9, 13.3] ],
51 [ 22, [3.1, 7.1], [3.2, 13.4] ],
52 [ 26, [3.3, 7.2], [3.5, 13.6] ],
55 crewpunch_shaft_max_y = 7.5;
57 crewpunch_systematic_size_error = +0.36;
59 crewpunch_smallest_shape = crewpunch_shape[0];
60 crewpunch_biggest_shape = crewpunch_shape[len(crewpunch_shape)-1];
62 crewpunch_skew_angle = 3.5; //degrees
63 crewpunch_skew_yoff = +1.1; //mm
67 punch_dx = 0.5 * (-crewpunch_biggest_shape[2][0]
68 +crewpunch_biggest_shape[2][1]);
69 punch_dy = 0.5 * (+crewpunch_biggest_shape[1][1]
70 -crewpunch_biggest_shape[1][0]) + crewpunch_skew_yoff;
72 attach_ysz = holder_attach_walls*2 + holder_ctie_width;
74 holder_block_zsz = crewpunch_biggest_shape[0] - crewpunch_smallest_shape[0];
75 holder_xsz = crewpunch_biggest_shape[2][0] + crewpunch_biggest_shape[2][1] +
78 holder_skewangle_yextra = holder_xsz/2 * sin(abs(crewpunch_skew_angle));
80 holder_max_y = punch_dy + crewpunch_biggest_shape[1][0] + holder_min_wall
81 + crewpunch_systematic_size_error + holder_skewangle_yextra;
83 holder_attach_max_y = punch_dy
84 - max(crewpunch_biggest_shape[1][1], crewpunch_shaft_max_y)
85 - crewpunch_systematic_size_error - holder_skewangle_yextra;
87 holder_block_min_y = punch_dy
88 - crewpunch_biggest_shape[1][1] - holder_attach_near_wall +
89 - crewpunch_systematic_size_error - holder_skewangle_yextra;
91 holder_all_min_y = holder_attach_max_y - attach_ysz;
93 jig_max_y = max(holder_max_y + main_slop, strap_width/2) + edgewall_width;
94 jig_min_y = min(holder_all_min_y - main_slop, -strap_width/2) - edgewall_width;
96 jig_main_zsz = holder_block_zsz + punch_travel;
100 jig_iters = floor((jig_max_len - jig_ends_extra) / jig_interval);
107 ourslop = crewpunch_slop - crewpunch_systematic_size_error;
109 for(layer=crewpunch_shape){
110 translate([0,0, layer[0]]){
111 for(xind=[0,1]) //translate([xind?0:1,0,0])
112 for(yind=[0,1]) //translate([0,yind?0.5:0,0])
113 mirror([xind?1:0,0,0]) mirror([0,yind?0:1,0]){
114 translate([-0.1,-0.1,-0.1])
115 cube([0.1 + layer[2][xind] + ourslop,
116 0.1 + layer[1][1-yind] + ourslop,
124 module MaybeRoundedCube(sizes, roundedness){
125 if (roundedness > 0) {
126 translate([roundedness, roundedness, 0]){
128 cube([sizes[0] - roundedness*2,
129 sizes[1] - roundedness*2,
131 cylinder(h=0.05, r=roundedness, $fn=20);
139 module PunchHolder(cutouts=true){
140 roundedness = cutouts ? holder_corner_round : 0;
142 translate([-holder_xsz/2, holder_block_min_y, 0])
143 MaybeRoundedCube([holder_xsz,
144 holder_max_y - holder_block_min_y,
148 rotate([0,0,-crewpunch_skew_angle])
151 -crewpunch_smallest_shape[0]])
155 translate([-holder_attach_xsz/2, holder_all_min_y, 0])
156 MaybeRoundedCube([holder_attach_xsz,
158 holder_block_zsz + punch_travel
159 + holder_ctie_thick + holder_attach_roof + 1],
163 holder_all_min_y + holder_attach_walls,
164 holder_block_zsz + punch_travel])
165 cube([60, holder_ctie_width, holder_ctie_thick]);
169 module RegistrationGroove(l){
170 // runs along the +ve X axis for length l but at correct z pos
171 translate([0, 0, jig_main_zsz + 0.1]) {
173 linear_extrude(height=l)
174 polygon([[-registrationgroove_width/2, 0],
175 [ +registrationgroove_width/2, 0],
176 [ 0, -registrationgroove_depth ]]);
182 translate([-(jig_interval/2 + jig_overlap),
185 cube([jig_interval + 2,
186 jig_max_y - jig_min_y,
187 jig_main_zsz + strap_thick]);
189 cube([main_slop*2, main_slop*2, 50], center=true);
192 translate([-100, -strap_width/2, -10])
193 cube([200, strap_width, 10]);
194 translate([-100,0,0])
195 RegistrationGroove(200);
196 for (xfrac=[-1/4,0,+1/4])
197 translate([jig_interval * xfrac, -100, 0])
199 RegistrationGroove(200);
203 module RegistrationProtrusion(){
204 // points towards the positive x axis
205 xsz = registrationprotrusion_poke;
206 ysz = registrationprotrusion_poke;
207 diag_sz = xsz * sqrt(2);
208 zsz = diag_sz / registrationprotrusion_slope;
210 translate([0, 0, 0.1]){
211 linear_extrude(height=0.1)
212 polygon([[ 0, -ysz ],
215 translate([-0.1, 0, zsz ])
224 for(yfrac=[-1/2, 0, 1/2]){
226 ? jig_interval * (jig_iters - 0.5)
230 rotate([0,0, end ? 0 : 180])
231 translate([ jig_overlap, 0, 0 ])
232 RegistrationProtrusion();
235 for (i=[0:jig_iters-1]) {
236 translate([jig_interval * i, 0, 0])
241 module JigT(){ ////toplevel
243 translate([0,0,jig_main_zsz])
248 module PunchHolderT(){ ////toplevel
252 module Demo(){ ////toplevel
257 module Kit(){ ////toplevel
260 translate([(jig_iters-1)*jig_interval/2,
261 jig_min_y - holder_max_y - 5,
269 //PunchHolder(false);
274 //RegistrationProtrusion();