finbox mold refactoring

Surf-Fins-10inch.json

@@ -42,6 +42,59 @@
             "show_curve_points": "false",
             "show_debug_layers": "false",
             "start": "[0, 0]"
+        },
+        "New set 2": {
+            "$fn": "64",
+            "base_extra_thickness": "40",
+            "base_tickness": "8",
+            "build_box": "false",
+            "build_fin": "false",
+            "build_mold": "true",
+            "draw_profile": "false",
+            "fin_back_angle": "20",
+            "fin_back_height": "30",
+            "fin_back_strength": "30",
+            "fin_back_widthdraw": "20",
+            "fin_base": "130",
+            "fin_counter_angle": "30",
+            "fin_counter_strength": "10",
+            "fin_edge_angle": "30",
+            "fin_edge_strength": "30",
+            "fin_edge_withdraw": "20",
+            "fin_end_angle": "110",
+            "fin_end_strength": "30",
+            "fin_height": "254",
+            "fin_start_angle": "70",
+            "fin_sweep": "25",
+            "fin_thickness": "9",
+            "fin_top_withdraw": "35",
+            "fin_width": "270",
+            "fin_width_tip": "5",
+            "height": "25",
+            "merge_holes_diameter": "6",
+            "mirror_vec": "[1, 1, 0]",
+            "mold_base_height": "10",
+            "mold_extra_width": "15",
+            "mold_part": "all",
+            "mold_piston_height": "10",
+            "mold_top_height": "5",
+            "parts": "all",
+            "pin_back": "9",
+            "pin_depth": "16.399999999999999",
+            "pin_dia": "3",
+            "piston_depth": "5",
+            "printable": "true",
+            "render_drill_template": "false",
+            "resin_escape_diameter": "4",
+            "scale_factor": "1",
+            "screw_dia": "4.5",
+            "screw_pos": "9.5999999999999996",
+            "show_curve_points": "false",
+            "show_debug_layers": "false",
+            "start": "[0, 0]",
+            "tab_height": "13",
+            "thick": "9.1999999999999993",
+            "thick_cut": "1"
         }
     }
 }

Surf-Fins-10inch.scad

@@ -62,7 +62,7 @@ fin_counter_strength = 10;  // Length [Point 2]
 
 
 fin_width_tip   = 5; // Width at the tip in mm
-fin_thickness   = 10; // Thickness of the fin in mm
+fin_thickness   = 9; // Thickness of the fin in mm
 
 fin_end_angle   = 110;
 fin_end_strength   = 30;
@@ -222,15 +222,18 @@ points = flatten([
     // *****************   
     bez_end(end_point,75,40),    
 ]);
-profile_curve  = translate_path( addBase(asCurve(points,32)),-fin_base/2,0 );
-//profile_curve  = translate_path( asCurve(points,32),-fin_base/2,0 );
-//profile_curve  = resample_path(translate_path( asCurve(points,32),-fin_base/2,0 ),64);
 
-assert(is_path_simple(profile_curve));
+profile_curve_with_base  = translate_path( addBase(asCurve(points,32)),-fin_base/2,0 );
+profile  = translate_path( asCurve(points,32),-fin_base/2,0 );
+
+//profile_curve_with_base  = translate_path( asCurve(points,32),-fin_base/2,0 );
+//profile_curve_with_base  = resample_path(translate_path( asCurve(points,32),-fin_base/2,0 ),64);
+
+assert(is_path_simple(profile_curve_with_base));
 
 
 if (show_curve_points)
-    color("Blue")move_copies(profile_curve) circle($fn=16);
+    color("Blue")move_copies(profile_curve_with_base) circle($fn=16);
 
 
 // Draw fin profile
@@ -238,60 +241,34 @@ if (draw_profile) {
     //left(425) drawProfile( points, true  );
     
     
-    layer0 = expandPath(profile_curve,-2);
+    layer0 = expandPath(profile_curve_with_base,-2);
-    layer1 = expandPath(profile_curve,-8);
+    layer1 = expandPath(profile_curve_with_base,-8);
-    layer2 = expandPath(profile_curve,-15);
+    layer2 = expandPath(profile_curve_with_base,-15);
-    layer3 = expandPath(profile_curve,-30);
+    layer3 = expandPath(profile_curve_with_base,-30);
-    layer4 = expandPath(profile_curve,-40);
+    layer4 = expandPath(profile_curve_with_base,-40);
     
     back(10) showDebugPath(layer0);
     
     
     left(500) {
-        color("Red") polygon(profile_curve);
+        color("Red") polygon(profile_curve_with_base);
         up(10) polygon(layer0);
         up(20) color("Yellow") polygon(layer1);
         up(30) color("Brown") polygon(layer2);
     }
     
-    layers = [profile_curve,layer0,layer1,layer2,layer3,layer4];
+    layers = [profile_curve_with_base,layer0,layer1,layer2,layer3,layer4];
     
-    left (800) color ("Green") polygon(profile_curve);
+    left (800) color ("Green") polygon(profile_curve_with_base);
     
-       left (1000) color ("Green") shell(10) polygon(profile_curve);
+       left (1000) color ("Green") shell(10) polygon(profile_curve_with_base);
     
 }    
 
 
 
-/**
- * Draws a profile based on Bezier path points with optional debug visualization.
- * 
- * @param points - Array of points defining the Bezier path.
- * @param debug - Boolean flag to enable/disable debug visualization. Defaults to true.
- * 
- * This module:
- * - Calculates the closest point on the Bezier path to a fixed point.
- * - Draws the Bezier path with debug information if debug is true.
- * - Optionally shows spheres at specific points for debugging (currently commented out).
- */
-module drawProfile( points,debug = true ){
 
 
-    debugPoint (start,      "Start",    "Red"   );
-    debugPoint (top_point,  "Top",      "Blue"  );
-    debugPoint (edge_point, "Edge",     "Brown" );
-    debugPoint (counter_edge_point,     "Counter Edge", "Brown" );
-    debugPoint (tail_point, "Tail",     "Yellow" );
-    debugPoint (end_point,  "End",      "Yellow" );
-    
-    //pt  = [100,0];
-    //pos = bezpath_closest_point(points, pt);
-    //xy  = bezpath_points(points,pos[0],pos[1]);
-    
-    debug_bezier(points, N=3,width=1.2);
-}
-
 // *****************
 // *  Fin Drawing  *
 // *****************
@@ -319,8 +296,18 @@ module buildCompletFin() {
 
 
 module buildBox() {
-    left(80) xflip() 
+    left(80) {
-        finfit(fin_base+20, [1,1,0],false,false);
+        xflip() {     
+            finfit(fin_base+20, [1,1,0],false,false);
+        }        
+    
+        //up(20) tab_cut();
+    }
+        
+}
+module buildBoxMold() {
+    zrot(-90) chinook_profile(fin_base+20);
+    zrot(-90) up(-2) offset(chinook_profile(fin_base+20),delta=5);
 }
 
 
@@ -329,18 +316,21 @@ module buildBox() {
  * 
  */
 module buildMold() {
-    
-    moldContour =  expandPath(profile_curve,mold_extra_width);
-    showDebugPath(moldContour);
     moldHeight = 10;
     skirtHeight = 30;
+
+    
+    moldContour =  expandPath(profile,mold_extra_width);
     buildMoldSkirt(skirtHeight,mold_extra_width,3);
     
     if (mold_part != "top") {
         difference() {
             union() {
                 down(moldHeight) linear_extrude (moldHeight) polygon(moldContour);  // bottom 
-                back(5) left(95) cube([20+10,25,moldHeight],anchor=BACK+TOP);          // Box shell
+                //back(5) left(95) cube([20+10,25,moldHeight],anchor=BACK+TOP);          // Box shell
+                
+                up(5) color("Yellow") left(80) buildBoxMold();
+                
             };
             buildCompletFin();
         }
@@ -371,11 +361,11 @@ module buildMold() {
     */    
 }
 module buildMoldSkirt( height,offset,thickness ) {
-    outside = expandPath(profile_curve,offset);
+    outside = expandPath(profile,offset);
-    inside = expandPath(profile_curve,offset-thickness);
+    inside = expandPath(profile,offset-thickness);
     down(height) {
         // Skirt
-        linear_extrude (height) difference() {
+        linear_extrude (height-thick/2) difference() {
             polygon(outside);
             polygon(inside);
         };
@@ -474,7 +464,7 @@ module buildDrillTemplate() {
 // *****************
 module bottomInsert() {
     debug=true;
-    layer_profile       = profile_curve; 
+    layer_profile       = profile_curve_with_base; 
     skin( [ layer_profile,expandPath(layer_profile,3) ], z=[0,piston_depth], slices=0 )
        up(OFFSET) 
         buildFinSide(true)
@@ -486,7 +476,7 @@ module bottomInsert() {
 // *****************
 module topPiston() {
     debug=true;
-    layer_profile       = profile_curve; 
+    layer_profile       = profile_curve_with_base; 
     difference() {
         skin( [ layer_profile,expandPath(layer_profile,3) ], z=[0,piston_depth], slices=0 );
         down(OFFSET)
@@ -512,14 +502,14 @@ module buildFin( thickness ) {
  */
 module buildFinSide(thickness,flip=false) {
 
-    //profile_curve1 = subdivide_path (profile_curve,500);
+    //profile_curve_with_base1 = subdivide_path (profile_curve_with_base,500);
     
     //if (false)
     mirror([0,0,flip ? 1 : 0])
         color(flip ? "Gray" : "LightGray")
         ellipse_extrude( thickness / 2 /*,height=2*/,center=false,twist=-7) 
             //zrot(30)
-            polygon( profile_curve);
+            polygon( profile_curve_with_base);
 } 
 
 module resin_escape(length) { 
@@ -541,26 +531,9 @@ module drilling(){
 
         );
 }
-/*
-echo ("bez_begin([-50,0],[0,-20])",bez_begin([-50,0],[0,-20]));
-echo ("bez_begin([-50,0],[0,-20])",
-
-
-    flatten([
-        bez_begin([-50,0],[0,-20]),
-        bez_end([-50,0],[0,-20])
-    ])
-    
-);
-*/
-echo ("bez_tang([0,0],70,80)",bez_tang(counter_edge_point,60+180,30));
-echo ("point 1 ",points[8]);
-echo ("point 2",points[9]);
-echo ("point 3",points[10]);
 
 function addBase(path) = concat(path,[[fin_base,-base_extra_thickness],[0,-base_extra_thickness]]);
 
-
     
 // Function to create a parallel bezier curve offset by a given amount
 function offset_bezier_points(points, offset_distance, normal=[0,0,1]) =
@@ -604,7 +577,7 @@ function make_bezier_patch_from_curve(base_points, width, length_steps=32, width
     
 if (false) {
 
-    //vnf = bezier_vnf(profile_curve, splinesteps=10);
+    //vnf = bezier_vnf(profile_curve_with_base, splinesteps=10);
     
     /*
     vnf = make_bezier_patch_from_curve(points, width=10);
@@ -614,9 +587,9 @@ if (false) {
     } 
   */  
   /*
-  polygon(profile_curve);
+  polygon(profile_curve_with_base);
-        vnf2 =vnf_from_region(polygon(profile_curve));
+        vnf2 =vnf_from_region(polygon(profile_curve_with_base));
-    //vnf2 = vnf_from_polygons(profile_curve, fast=true);
+    //vnf2 = vnf_from_polygons(profile_curve_with_base, fast=true);
     vnf_polyhedron(vnf2);    
     */
     
@@ -646,6 +619,33 @@ if (false) {
 
 }    
 
+/**
+ * Draws a profile based on Bezier path points with optional debug visualization.
+ * 
+ * @param points - Array of points defining the Bezier path.
+ * @param debug - Boolean flag to enable/disable debug visualization. Defaults to true.
+ * 
+ * This module:
+ * - Calculates the closest point on the Bezier path to a fixed point.
+ * - Draws the Bezier path with debug information if debug is true.
+ * - Optionally shows spheres at specific points for debugging (currently commented out).
+ */
+module drawProfile( points,debug = true ){
+
+
+    debugPoint (start,      "Start",    "Red"   );
+    debugPoint (top_point,  "Top",      "Blue"  );
+    debugPoint (edge_point, "Edge",     "Brown" );
+    debugPoint (counter_edge_point,     "Counter Edge", "Brown" );
+    debugPoint (tail_point, "Tail",     "Yellow" );
+    debugPoint (end_point,  "End",      "Yellow" );
+    
+    //pt  = [100,0];
+    //pos = bezpath_closest_point(points, pt);
+    //xy  = bezpath_points(points,pos[0],pos[1]);
+    
+    debug_bezier(points, N=3,width=1.2);
+}
 
     
     

lib/chinook.scad

@@ -1,54 +1,79 @@
-module chinook(length,screw = true,pin=true)
+
-{
+include <BOSL2/std.scad>;
-    difference()
-    {
-        base_cube(length);
-        tab_cut();
-        if (screw) screw_cut();
-        back_round_cut(length);
-        if (pin) pin_cut(length);
-        thickness_cut(length, thick/2);
-        thickness_cut(length, -thick/2);
-    }
-}
 
 module finfit(base_length, mirror_vec,screw = true,pin=true)
 {
     front_offset = tab_length;
     length = base_length + tab_length;
-    echo ("length:",length);
     mirror(mirror_vec)
-    translate([0,-front_offset, 0])
+        translate([0,-front_offset, 0])
-    chinook( length, screw ,pin );
+            chinook( length, screw ,pin );
 }
 
-module base_cube(BaseLength)
+module chinook(length,screw = true,pin=true,thick = 9.2,height=25,tab_height=13,)
+{
+    difference()
+    {
+        base_cube( length, thick, height );
+        tab_cut( thick ,height, tab_height );
+        if (screw) 
+            screw_cut(tab_height);
+        back_round_cut(length,thick,height);
+        if (pin) 
+            pin_cut(length,tab_height);
+        thickness_cut(length,height, thick/2);
+        thickness_cut(length,height, -thick/2);
+    }
+}
+
+module chinook_profile(length,thick = 9.2,height=25,tab_height=13,tab_round=13,tab_length=9.6*2)
+{
+    difference(){ 
+        rect(
+            [height,length],
+            rounding=[tab_round,0,0,0],
+            anchor=BOTTOM+LEFT
+        )
+        {
+            align(RIGHT+BOTTOM,inside=true,shiftout=0.1) 
+                rect( [ height-tab_height, tab_length+tab_round ],rounding=[0,tab_round-1,0,0] );
+        }
+    }    
+  
+    //region(difference(shape1,shape2));
+    
+ }
+
+module base_cube( length,thick,height )
 {
     translate([0,0,-thick/2])
-    cube(size=[height,
+        cube(
-               BaseLength,
+            size=[
-               thick],
+                height,
-         center=false);
+                length,
+                thick
+            ],
+            center=false
+        );
 }
 
-module tab_cut()
+module tab_cut( thick, height,tab_height,tab_round=13,tab_length=9.6*2 )
 {
     translate([tab_height,0,-thick/2*1.1])
     union()
     {
         translate([0,-thick,0])
-        cube(size=[height,
+            cube(
-                   tab_length+thick,
+                size=[height, tab_length+thick, thick*1.1],
-                   thick*1.1],
              center=false);
         translate([tab_round,tab_length,0])
-        cylinder(h=thick*1.1,
+            cylinder(h=thick*1.1,r=tab_round,center=false);
-                 r=tab_round,
-                 center=false);
     }
 }
 
-module screw_cut()
+
+
+module screw_cut(tab_height,screw_pos=9.6,screw_dia=4.5)
 {
     translate([tab_height/2,screw_pos,0])
     rotate([0,90,0])
@@ -57,7 +82,7 @@ module screw_cut()
              center=true);
 }
 
-module back_round_cut(BaseLength)
+module back_round_cut(BaseLength,thick,height,tab_round=13)
 {
     translate([height-tab_round,
                BaseLength-tab_round,
@@ -74,25 +99,44 @@ module back_round_cut(BaseLength)
     }
 }
 
-module pin_cut(BaseLength)
+module pin_cut(BaseLength,tab_height,pin_dia=3, pin_back=9,pin_depth=16.4)
 {
     translate([pin_depth,
                BaseLength-pin_back,
                0])
-    rotate([0,0,0])
+        rotate([0,0,0])
-    cylinder(h=tab_height*1.1,
+            cylinder(
-             d=pin_dia,
+                h=tab_height*1.1,
-             center=true);
+                d=pin_dia,
+                center=true
+            );
 }
 
-module thickness_cut(BaseLength, zOffset)
+module thickness_cut(BaseLength,height, zOffset,pin_depth=16.4, pin_back=9,thick_cut = 1 )
 {
-    translate([pin_depth,
+    translate([
-               BaseLength-pin_back,
+        pin_depth,
-               zOffset])
+        BaseLength-pin_back,
-    rotate([0,0,45])
+        zOffset])
-    cube(size=[pin_depth*2.2,
+        rotate([0,0,45])
-               height*3,
+            cube(
-               thick_cut],
+                size=[
-         center=true);
+                    pin_depth*2.2,
+                    height*3,
+                    thick_cut
+                ],
+                center=true
+            );
 }
+
+if (true) {
+   
+   chinook(130+20); 
+   //up(5.2) left() color("Yellow")chinook_profile(130+20); 
+
+
+}
+
+
+
+

lib/finbox_us.scad

@@ -0,0 +1,157 @@
+
+include <BOSL2/std.scad>;
+include <BOSL2/beziers.scad>;
+
+include <Round-Anything/polyround.scad>
+
+
+$fn=64;
+
+OFFSET=0.01;
+
+/**
+ * US Box profile
+ 
+ * @param length - Length of the fin without the tab and back space
+ *
+ **/
+module boxProfileUS( length ,height=23, tabHeight = 8,tabLength = 20, backRounding = 8, backExtra = 10 ) {
+
+    
+    tabExtra = opp_ang_to_adj(height-tabHeight,45);
+    points = [
+        [ -tabLength                    , 0             ,1],            // 0
+        [ length+backExtra              , 0             ,2],            // 1
+        [ length+backExtra              , -height       ,backRounding], // 2
+        [ tabExtra                      , -height       ,4],            // 3
+        [ 0                             , -tabHeight    ,4],            // 4
+        [ -tabLength                    , -tabHeight    ,1]             // 5
+    ];
+    polygon(
+        polyRound(points)
+    );
+}    
+
+function profileUS( length,height=23,tabHeight = 8,tabLength = 20, backRounding = 8, backExtra = 10 ) = polyRound([
+        [ -tabLength                    , 0             ,1],            // 0
+        [ length+backExtra              , 0             ,2],            // 1
+        [ length+backExtra              , -height       ,backRounding], // 2
+        [ opp_ang_to_adj(height-tabHeight,45) , -height ,4],            // 3
+        [ 0                             , -tabHeight    ,4],            // 4
+        [ -tabLength                    , -tabHeight    ,1]             // 5
+    ]);
+
+
+module usBox( length, height=23, thickness = 9, tabLength = 20,pinDiameter = 5,pinInset = 8, backExtra = 10,cutReduction = 0.5,screw_diameter=4.5,drill = true, color="Grey" ) {
+    color(color) mirror_copy([0,0,1], offset=-OFFSET) difference() {
+        linear_extrude ( height = thickness/2 ) boxProfileUS( length, tabLength = tabLength, height=height, backExtra=backExtra );
+        // Thickness cut
+        translate([length + backExtra + OFFSET,-OFFSET,thickness/2-cutReduction+OFFSET])
+            thickness_cut( cutReduction , height );
+        // Pin drill
+        if (drill) translate([length+backExtra-pinInset,-height+pinInset,0]) color("Red")
+            cyl(h=thickness*2,d=pinDiameter,$fn=32);
+            
+        // Screw Cut
+        if (drill) translate ([-tabLength/2,-height/2+OFFSET,0]) color ("Red") cyl( h=height, d=screw_diameter, orient=FRONT );    
+    }
+}
+
+
+module usBoxMold( length, height=23, thickness = 9, moldThickness = 4,tabLength = 20,part = "bottom",skirtAngle=80 ) {
+
+    moldHeight = thickness + 2 * moldThickness;
+    skirtHeight = 3 * thickness;
+    deviation = opp_ang_to_adj (skirtHeight,skirtAngle);    // Skirt devitation
+    
+    baseInt = profileUS (length);
+    baseExt = offset(baseInt,delta=moldThickness            , chamfer=false, same_length=true );   
+    topInt  = offset(baseInt,delta=deviation                , chamfer=false, same_length=true );    
+    topExt  = offset(baseInt,delta=deviation+moldThickness  , chamfer=false, same_length=true );
+    
+    union() {
+        difference() {
+            // Mold
+            {
+                if ( part == "bottom")
+                    down (moldHeight/2) linear_extrude(moldHeight)    
+                        offset(r=moldThickness) 
+                            boxProfileUS( length, height );
+                if ( part == "top") {
+                    //baseInt = profileUS (length);
+                    //baseInt = profileUS (length);
+                    //topInt  = offset(baseInt,delta=-deviation,chamfer=false,same_length=true);
+                    baseInt2  = offset(baseInt,delta=-moldThickness,chamfer=false,same_length=true);
+                    topInt2  = offset(baseInt,delta=deviation-moldThickness,chamfer=false,same_length=true);
+                    
+                    difference(){
+                        skin([baseInt   , topInt    ],z=[0,skirtHeight],slices=0);
+                        skin([baseInt2  , topInt2   ],z=[thickness/2,skirtHeight+OFFSET],slices=0);
+                    }
+                    
+                    /*    
+                    down (moldHeight/2) linear_extrude(moldHeight)    
+                        offset(r=moldThickness) 
+                            boxProfileUS( length, height );                            
+                    */        
+                }                    
+            }        
+            // US Box to subtract
+            usBox(length,height,drill=false,color="Red");
+
+            // Mask Top  
+            verticalMask = 
+                part == "bottom" ? 0 : 
+                part == "top"    ? moldHeight : 
+                100;        
+            down( verticalMask )
+                linear_extrude( moldHeight )    
+                    offset( r = moldThickness*2 ) 
+                        boxProfileUS( length, height );                    
+        }
+        
+        if ( part == "bottom") {
+   // offset is a function
+            
+            //topInt  = offset(baseInt,delta=deviation,chamfer=false,same_length=true);
+            showSkirt = true;
+            if (showSkirt) difference(){
+                skin([baseExt,topExt],z=[0,skirtHeight],slices=0);
+                skin([baseInt,topInt],z=[0,skirtHeight+OFFSET],slices=0);
+            }
+        }
+        if ( part == "top") {
+        
+        }
+    }       
+    
+}
+
+//test = profileUS (100);
+//test2 = offset(test,30);
+//region1 = 
+//region([test,test2]);
+//polygon(region1);
+
+
+
+module thickness_cut(thickness,height) {
+    color("Orange")
+    linear_extrude(thickness) 
+        polygon([
+           [0           , 0         ],
+           [0           , -height   ],
+           [-height*2   , -height   ] 
+        ]);
+}
+
+
+
+
+//boxProfileUS( length= 188);
+
+//usBox( 130,drill=false );
+usBoxMold( 130,part="top" );
+down(50) usBoxMold( 130,part="bottom" );
+
+