Bottom mold mask refining

Surf-Fins-10inch.json

@@ -95,6 +95,59 @@
             "tab_height": "13",
             "thick": "9.1999999999999993",
             "thick_cut": "1"
+        },
+        "New set 3": {
+            "$fn": "64",
+            "base_extra_thickness": "20",
+            "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

@@ -12,9 +12,10 @@ include <DotScad/src/ellipse_extrude.scad>;
 include <DotScad/src/loft.scad>;
 
 include <scad-utils/morphology.scad>;
-include <common.scad>
+include <common.scad>;
 
 include <./lib/chinook.scad> // US Box
+include <./lib/finbox_us.scad> // US Box
 
 
 // https://github.com/BelfrySCAD/BOSL2/wiki/Tutorial-Beziers_for_Beginners
@@ -76,7 +77,7 @@ fin_back_strength=30;
 /* [Base Specs] */
 
 base_tickness=8; 
-base_extra_thickness=40;
+base_extra_thickness=20;
 
 
 // ---------------------*/
@@ -96,6 +97,8 @@ resin_escape_diameter   = 4;
 merge_holes_diameter = 6;
 piston_depth = 5;
 
+skirt_angle=80;
+
 // ---------------------*/
 /*        [US Box]        */
 // ---------------------*/
@@ -262,13 +265,10 @@ if (draw_profile) {
     left (800) color ("Green") polygon(profile_curve_with_base);
     
        left (1000) color ("Green") shell(10) polygon(profile_curve_with_base);
-    
 }    
 
 
 
-
-
 // *****************
 // *  Fin Drawing  *
 // *****************
@@ -290,12 +290,13 @@ if ( render_drill_template )    buildDrillTemplate();
 module buildCompletFin() {
     union(){
         buildFin( fin_thickness );
-        buildBox();
+        //buildBox();
     }
 }
 
 
 module buildBox() {
+    /*
     left(80) {
         xflip() {     
             finfit(fin_base+20, [1,1,0],false,false);
@@ -303,14 +304,37 @@ module buildBox() {
     
         //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);
+    // To be defined
 }
 
 
+
+
+/**
+ * Remove bottom part of the fin mold to let the box mold do the job
+ *
+ */
+module moldBottomMask(moldThickness = 3,height,angle) {
+
+    // Remove bottom part 
+    //color("Red") cube([fin_width,base_extra_thickness,80],anchor=BACK);
+    deviation = opp_ang_to_adj (height,angle);
+    //back(moldThickness)
+    back(-1)
+    down(OFFSET)
+    //up(2)
+    color ("Blue") prismoid(
+                size1=[fin_width/2*1.2, moldThickness*2], 
+                size2=[fin_width/2*1.2, moldThickness*2+ 2*deviation], 
+                h=height+OFFSET*2 
+            );
+}
+
 /**
  * Build mold
  * 
@@ -323,19 +347,49 @@ module buildMold() {
     moldContour =  expandPath(profile,mold_extra_width);
     buildMoldSkirt(skirtHeight,mold_extra_width,3);
     
+    // Bottom Mold
     if (mold_part != "top") {
+    
+        // Fin mold
         difference() {
             union() {
                 down(moldHeight) linear_extrude (moldHeight) polygon(moldContour);  // bottom 
                 //back(5) left(95) cube([20+10,25,moldHeight],anchor=BACK+TOP);          // Box shell
+                difference() {
+                    skirt( profile, moldThickness = 3 , angle = skirt_angle, moldDeep = fin_thickness );
+                    moldBottomMask(height=fin_thickness * 3,angle=skirt_angle);
                     
-                up(5) color("Yellow") left(80) buildBoxMold();
+                    
+                    //
+                    //moldJunctionMask(height=fin_thickness * 3,angle=skirt_angle);
+                }
                 
             };
+            // Remove Fin
             buildCompletFin();
         }
+        // Box mold
+        assert (fin_base,"fin_base missing");
+        echo ("fin_base----------",fin_base);
+        //          left(80) finBoxMold( length = 130, finLength = fin_base );
+        //diff() {
+        difference() {
+            left(80) finBoxMold( fin_base+30,skirtAngle = skirt_angle );
+            
+            // Remove junction between skirt
+            //tag("remove")
+            moldJunctionMask(height=fin_thickness * 3,angle=skirt_angle);
+            //tag("remove")        
+            buildCompletFin();       
+        }
+        //moldJunctionMask(height=fin_thickness * 3,angle=skirt_angle);
+        
+        
+        
     }
     
+    up(50) buildCompletFin();
+    
     //left(300) linear_extrude (skirtHeight) polygon(moldSkirtRegion);
     /*
     if (mold_part !=  "top") 
@@ -360,6 +414,24 @@ module buildMold() {
         }      
     */    
 }
+
+module moldJunctionMask(moldThickness = 3,height,angle){
+
+    deviation = opp_ang_to_adj (height,angle);
+    right(moldThickness)
+    left(moldThickness/2)
+    down(OFFSET)
+    //fwd(60)
+    //back(moldThickness*2-0.5)
+    back(moldThickness*1.2-OFFSET )
+        color("Red") 
+            prismoid(
+                size1=[fin_width/2-1.5*moldThickness, moldThickness*3+2*OFFSET], 
+                size2=[fin_width/2+1*deviation+0*moldThickness, /*moldThickness/2*/moldThickness * 3+deviation], 
+                h=height+OFFSET*3 
+            );
+}
+
 module buildMoldSkirt( height,offset,thickness ) {
     outside = expandPath(profile,offset);
     inside = expandPath(profile,offset-thickness);

common.scad

@@ -122,9 +122,11 @@ module print_path_points(path) {
  * Expand path 
  *
  * @param path - Original path
- * param delta - distance to expand
+ * @param delta - distance to expand
+ *
+ * Keep the same number of points
  */
-function expandPath(path,delta) = 
+function expandPath( path, delta ) = 
         offset(
             deduplicate(path),
             delta=delta,
@@ -153,3 +155,29 @@ function layerHeights(n, fin_thickness) =
         layer_height = fin_thickness / (n - 1)
     )
     [ for (i = [0 : n-1]) i * layer_height ];
+
+/**
+ * Make a skirt around a profile
+ *
+ * @param profile       - Path ot the mold
+ * @param moldThickness - Thickness of the mold
+ * @param angle         - Angle of the skirt starting from flat angle
+ * @param moldDeep      - Mold deep. Normally height of the skirt should be 3 times the thickness of the model
+ * @param side          - Bottom or top part of the mold
+ *
+ */ 
+module skirt( profile, moldThickness, angle, moldDeep, side = "bottom", heightFactor = 3 ) {
+    deviation = opp_ang_to_adj (height,angle);
+    skirtHeight = heightFactor * moldDeep;
+    if ( side == "bottom" ) {
+        lowInt  = profile;
+        lowExt  = expandPath( lowInt    , moldThickness  );
+        highInt = expandPath( lowInt    , deviation  );
+        highExt = expandPath( lowInt    , deviation + moldThickness  );
+        difference(){
+            skin([lowExt   , highExt   ], z=[0                          , skirtHeight]          , slices=0);
+            skin([lowInt   , highInt   ], z=[-OFFSET   , skirtHeight+OFFSET]   , slices=0);
+        }            
+    }
+}    
+    

lib/chinook.scad

@@ -129,13 +129,6 @@ module thickness_cut(BaseLength,height, zOffset,pin_depth=16.4, pin_back=9,thick
             );
 }
 
-if (true) {
-   
-   chinook(130+20); 
-   //up(5.2) left() color("Yellow")chinook_profile(130+20); 
-
-
-}
 
 
 

lib/finbox_us.scad

@@ -60,6 +60,8 @@ module usBox( length, height=23, thickness = 9, tabLength = 20,pinDiameter = 5,p
 
 module usBoxMold( length, height=23, thickness = 9, moldThickness = 4,tabLength = 20,part = "bottom",skirtAngle=80 ) {
 
+//assert(length == 130,"Not 130");
+
     moldHeight = thickness + 2 * moldThickness;
     skirtHeight = 3 * thickness;
     deviation = opp_ang_to_adj (skirtHeight,skirtAngle);    // Skirt devitation
@@ -86,7 +88,7 @@ module usBoxMold( length, height=23, thickness = 9, moldThickness = 4,tabLength
                     
                     difference(){
                         skin([baseInt   , topInt    ],z=[0,skirtHeight],slices=0);
-                        skin([baseInt2  , topInt2   ],z=[thickness/2,skirtHeight+OFFSET],slices=0);
+                        skin([baseInt2  , topInt2   ],z=[thickness/2+moldThickness,skirtHeight+OFFSET],slices=0);
                     }
                     
                     /*    
@@ -127,6 +129,15 @@ module usBoxMold( length, height=23, thickness = 9, moldThickness = 4,tabLength
     
 }
 
+module finBoxMold( length, finLength=-1, skirtAngle = 80, part="bottom") {
+
+    assert (finLength,"Missing 'finLength' parameter in finBoxMold module");
+    //if (part=="bottom") {
+    usBoxMold( length,part=part,skirtAngle=skirtAngle );
+    //}
+    
+}
+
 //test = profileUS (100);
 //test2 = offset(test,30);
 //region1 = 
@@ -151,7 +162,10 @@ module thickness_cut(thickness,height) {
 //boxProfileUS( length= 188);
 
 //usBox( 130,drill=false );
-usBoxMold( 130,part="top" );
+//usBoxMold( 130,part="top" );
-down(50) usBoxMold( 130,part="bottom" );
+
+
+
+//down(50) usBoxMold( 130,part="bottom" );