mold top

Surf-Fins-10inch.json

@@ -36,7 +36,6 @@
             "parts": "all",
             "piston_depth": "5",
             "printable": "false",
-            "render_drill_template": "false",
             "resin_escape_diameter": "4",
             "scale_factor": "1",
             "show_curve_points": "false",
@@ -84,7 +83,6 @@
             "pin_dia": "3",
             "piston_depth": "5",
             "printable": "true",
-            "render_drill_template": "false",
             "resin_escape_diameter": "4",
             "scale_factor": "1",
             "screw_dia": "4.5",
@@ -137,7 +135,6 @@
             "pin_dia": "3",
             "piston_depth": "5",
             "printable": "true",
-            "render_drill_template": "false",
             "resin_escape_diameter": "4",
             "scale_factor": "1",
             "screw_dia": "4.5",

Surf-Fins-10inch.scad

@@ -106,6 +106,8 @@ skirt_angle=80;
 // Dimensions in mm
 //length = 180;
 //length=fin_base;
+
+box_thickness = 9.6;
 height = 25;
 thick  = 9.2;
 mirror_vec = [1,1,0];
@@ -152,7 +154,6 @@ draw_profile = false;
 build_fin       = false;
 build_box       = false;
 build_mold     = true;
-render_drill_template     = false;
 
 parts           = "all";      // [all, top, bottom]
 
@@ -284,13 +285,14 @@ if ( build_box ) {
  * Render Mold
  */
 if ( build_mold )              buildMold();    
-if ( render_drill_template )    buildDrillTemplate();
 
 
 module buildCompletFin() {
-    union(){
+    difference(){
         buildFin( fin_thickness );
         //buildBox();
+        // Remove extra base
+        baseMask();
     }
 }
 
@@ -312,27 +314,32 @@ module buildBoxMold() {
     // To be defined
 }
 
+module baseMask() {
+    fwd(OFFSET) cube([fin_base*1.1,base_extra_thickness*1.1,fin_thickness*1.1],anchor=BACK);
+}
 
 
 
-/**
+module usBoxMask() {
- * Remove bottom part of the fin mold to let the box mold do the job
+    left(80) color("Blue") usBox(fin_base+30,thickness = box_thickness+2*OFFSET,drill=false);
- *
+}
+
+
+
+/*
+module bottomSupport() {
+    moldHeight = 10;
+    moldContour =  expandPath(profile,mold_extra_width);
+    down(moldHeight) 
+        linear_extrude (moldHeight) polygon(moldContour);  // bottom support
+}
 */
-module moldBottomMask(moldThickness = 3,height,angle) {
 
-    // Remove bottom part 
+module support( part ) {
-    //color("Red") cube([fin_width,base_extra_thickness,80],anchor=BACK);
+    moldHeight = 10;
-    deviation = opp_ang_to_adj (height,angle);
+    moldContour =  expandPath(profile,mold_extra_width);
-    //back(moldThickness)
+    down( (part == "bottom" ? 1 : 0) * moldHeight) 
-    back(-1)
+        linear_extrude (moldHeight) polygon(moldContour);  // bottom support
-    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 
-            );
 }
 
 /**
@@ -340,55 +347,44 @@ module moldBottomMask(moldThickness = 3,height,angle) {
  * 
  */
 module buildMold() {
-    moldHeight = 10;
-    skirtHeight = 30;
-
-    
-    moldContour =  expandPath(profile,mold_extra_width);
-    buildMoldSkirt(skirtHeight,mold_extra_width,3);
-    
     // Bottom Mold
     if (mold_part != "top") {
-    
         // Fin mold
         difference() {
-            union() {
+            support(part="bottom");
-                down(moldHeight) linear_extrude (moldHeight) polygon(moldContour);  // bottom 
+            usBoxMask();
-                //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);
-                    
-                    
-                    //
-                    //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 );
+            left(80)  finBoxMold( fin_base+30,part="bottom",skirt=false );
-            
+            // Remove fin
-            // 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);
+        // Mold skirt
-        
+        moldSkirt( part="bottom" );
-        
+    }
+    // Top
+    if (mold_part != "bottom") up(80) {
+        difference(){
+            support(part="top");
+            usBoxMask();
+            buildCompletFin();
             
         }    
+        // Box mold
+        difference() {
+            left(80)  finBoxMold( fin_base+30,part="top",skirt=false );
+            // Remove fin
+            //buildCompletFin(); 
+        }
+        // Mold skirt
+        down( fin_thickness * 3 ) moldSkirt( part="top" );    
+    }
     
-    up(50) buildCompletFin();
+    
+    
+    //up(50) buildCompletFin();
     
     //left(300) linear_extrude (skirtHeight) polygon(moldSkirtRegion);
     /*
@@ -415,6 +411,33 @@ module buildMold() {
     */    
 }
 
+/**
+ * Build the piston skirt 
+ * 
+ * @param part   -  Part could be 'top' or 'bottom'
+ */
+module moldSkirt( part ){
+    assert( part , "'part' parameter should be defined in mold skirt");
+    
+    box_profile         = move([-80,0],profileUS (fin_base+30));
+    finAndBoxProfile    = path_merge_collinear(union([box_profile,profile]));    
+    
+    //if (part == "bottom") {
+
+    skirt( finAndBoxProfile, side = part ,moldThickness = 3 , angle = skirt_angle, moldDeep = fin_thickness );
+    //} else if (part == "top") {
+        
+    
+    //}
+    
+}
+
+//moldSkirt(part="top");
+
+
+
+
+
 module moldJunctionMask(moldThickness = 3,height,angle){
 
     deviation = opp_ang_to_adj (height,angle);
@@ -455,81 +478,6 @@ module buildMoldSkirt( height,offset,thickness ) {
     }
 }
 
-/**
- * Mold Case 
- *
- * @param height - Height of the case
- * @param bottom - Is bottom or top 
- */
-module case( height , bottom=true ) {
-    difference() {
-        diff() cuboid( [ mold_length, mold_width, height ],
-            rounding=4,
-            edges=[bottom ? BOTTOM: TOP],
-            anchor=TOP ){
-            // Drills
-            align(BOTTOM,[FRONT+LEFT,FRONT+RIGHT,BACK+LEFT,BACK+RIGHT],inset=10,overlap=-OFFSET)
-                color("orange") 
-                    tag("remove") 
-                        drilling();
-        };
-        // Material holes
-        mirror([bottom ? 0:1,0,0])
-        back(38) left(55)
-                color("Red")
-                    up(OFFSET)
-                        rounded_triangle(radius=3, height=height+2*OFFSET);              
-        // Length hole                    
-        fwd(32) cuboid([120,10,50],rounding=5);
-        // Side holes
-        left(67) cuboid([10,40,50],rounding=5);
-        right(67) cuboid([10,40,50],rounding=5);
-   }
-}
-
-/**
- * Drill template
- * 
- */ 
-module buildDrillTemplate() {
-    
-    spacing         = 38.5;
-    drill_depth     = 15;
-    drill_diameter  = 6;
-    template_height  = 5;
-    
-    p1 = 20;
-    p2 = p1-spacing;
-    
-    mirror([0,0,printable ? 1 : 0]) difference() {
-    
-        left(1) color ("Orange") cuboid([fin_width+7,15,10],rounding=3);
-        down(OFFSET) {
-            hull(){
-                left(28) cylinder(h=template_height+2*OFFSET,r=drill_diameter/2);
-                left(55) cylinder(h=template_height+2*OFFSET,r=drill_diameter/2);
-            }
-            hull(){
-                left(12) cylinder(h=template_height+2*OFFSET,r=drill_diameter/2);
-                left(-10) cylinder(h=template_height+2*OFFSET,r=drill_diameter/2);
-            }
-            hull(){
-                left(-27) cylinder(h=template_height+2*OFFSET,r=drill_diameter/2);
-                left(-53) cylinder(h=template_height+2*OFFSET,r=drill_diameter/2);
-            }
-        }
-        xrot(-90) buildFin(fin_thickness + 2*CLEARING );
-        //left(60) cylinder(h=20,r=6/2);
-        up(template_height+OFFSET)
-        {
-            left(p1) 
-                cylinder(h=drill_depth+template_height,r=drill_diameter/2,orient=DOWN);
-            left(p2) 
-                cylinder(h=drill_depth,r=drill_diameter/2,orient=DOWN);
-        }
-    }
-}
-
 
 // *****************
 // * Bottom insert *
@@ -588,109 +536,10 @@ module resin_escape(length) {
     color ("Blue") cylinder(h=length, r=resin_escape_diameter/2);
 }
 
-// *****************
-// *  Drilling     *
-// *****************
-module drilling(){
-    /*fwd(20)*/ color("Red") /*up(mold_piston_height+5)*/ up(-OFFSET)
-    orient(DOWN)
-        threaded_rod(
-            d=merge_holes_diameter, 
-            l=drilling_length, 
-            pitch=1.5, 
-            anchor=BOTTOM,
-            //orient=BOTTOM
-
-        );
-}
 
 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]) =
-    [for (pt = points) pt + offset_distance * normal];
-
-// Function to create multiple parallel bezier curves
-function create_patch_points(base_points, width, steps=4) =
-    [for (i = [0:1:steps]) 
-        let(
-            t = i/steps,
-            offset = width * t
-        )
-        offset_bezier_points(base_points, offset)
-    ];
-
-// Create the bezier patch VNF
-function make_bezier_patch_from_curve(base_points, width, length_steps=32, width_steps=8) =
-    let(
-        // Generate parallel curves to form patch
-        patch_points = create_patch_points(base_points, width, width_steps),
-        // Generate points for each curve
-        curves_points = [for (curve_pts = patch_points)
-            bezier_points(curve_pts, length_steps)
-        ],
-        // Create vertices for VNF
-        vertices = flatten(curves_points),
-        // Calculate indices for faces
-        indices = [
-            for (i=[0:1:width_steps-1], j=[0:1:length_steps-1])
-            let(
-                idx00 = i*(length_steps+1) + j,
-                idx10 = (i+1)*(length_steps+1) + j,
-                idx11 = (i+1)*(length_steps+1) + (j+1),
-                idx01 = i*(length_steps+1) + (j+1)
-            )
-            each [[idx00, idx10, idx11, idx01]]
-        ]
-    )
-    [vertices, indices];
-    
-    
-if (false) {
-
-    //vnf = bezier_vnf(profile_curve_with_base, splinesteps=10);
-    
-    /*
-    vnf = make_bezier_patch_from_curve(points, width=10);
-    back (100) {
-        cube([20,20,20]);
-        vnf_polyhedron(vnf);
-    } 
-  */  
-  /*
-  polygon(profile_curve_with_base);
-        vnf2 =vnf_from_region(polygon(profile_curve_with_base));
-    //vnf2 = vnf_from_polygons(profile_curve_with_base, fast=true);
-    vnf_polyhedron(vnf2);    
-    */
-    
-    //curve_points = bezier_curve(points,N=3, splinesteps=32); 
-    curve_points = bezpath_curve(points,N=3, splinesteps=32); 
-    curve_points2 = [ for(p = curve_points) [p.x, p.y, 0]]; // Offset by 1 in Z
-    //echo ("curve_points",curve_points);
-    curve_points_offset = [ for(p = curve_points) [p.x, p.y, (p.z != undef ? p.z : 0) + 1 ]]; // Offset by 1 in Z
-
-// Combine original and offset points to form a 2D array for a simple patch
-    patch_points = [
-        curve_points,
-        curve_points_offset
-    ];
-    //echo ("patch_points",patch_points);
-    //echo ("curve_points_offset",curve_points_offset);
-    echo ("curve_points2",curve_points2);
-    echo ("length curve_points2",len(curve_points2));
-   
-    //vnf_5 = bezier_vnf(patch_points, caps=false, splinesteps=10);
-    //vnf_5 = bezier_vnf(curve_points2, splinesteps=10);
-    echo ("is_bezier_patch",is_bezier_patch(curve_points));
-    echo ("is_bezier_patch",is_bezier_patch(curve_points2));
-    
-    //vnf_5 = bezier_vnf(curve_points_offset, splinesteps=10);
-    
-
-}    
-
 /**
  * Draws a profile based on Bezier path points with optional debug visualization.
  * 
@@ -721,3 +570,7 @@ module drawProfile( points,debug = true ){
 
 
 
+
+
+    
+    

common.scad

@@ -1,5 +1,6 @@
 
 
+include <BOSL2/std.scad>;
 
 // Constants
 
@@ -166,18 +167,53 @@ function layerHeights(n, fin_thickness) =
  * @param side          - Bottom or top part of the mold
  *
  */ 
-module skirt( profile, moldThickness, angle, moldDeep, side = "bottom", heightFactor = 3 ) {
+module skirt( profile, moldThickness = 4 , angle = 45 , moldDeep, side = "bottom", heightFactor = 3, clearance = 0.2 ) {
+    height = heightFactor * moldDeep;
+    echo ("height",height);
     deviation = opp_ang_to_adj (height,angle);
-    skirtHeight = heightFactor * moldDeep;
+//    deviation = 3;
+    
     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([lowExt   , highExt   ], z=[0          , height        ] , slices=0);
-            skin([lowInt   , highInt   ], z=[-OFFSET   , skirtHeight+OFFSET]   , slices=0);
+            skin([lowInt   , highInt   ], z=[-OFFSET    , height+OFFSET ] , slices=0);
         }            
+    } else if ( side == "top" ) {
+        lowInt  = expandPath( profile   , -moldThickness  );
+        lowExt  = expandPath( profile   , -clearance  );
+        highInt = expandPath( profile    , +deviation-moldThickness  );
+        highExt = expandPath( profile    , +deviation -clearance  );
+        difference(){
+            skin([lowExt   , highExt   ], z=[0          , height        ] , slices=0);
+            skin([lowInt   , highInt   ], z=[-OFFSET    , height+OFFSET ] , slices=0);
+        }            
+        
     }
 }    
 
+if ( false ) {
+    skirt(
+        rect([30,30]),
+        moldDeep=5,
+        moldThickness = 3,
+        side="bottom"
+    );
+    up(1)
+    skirt(
+        rect([30,30]),
+        moldDeep=5,
+        moldThickness = 3,
+        side="top",
+        clearance=1
+        
+    );
+}
+
+
+
+
+    

lib/finbox_us.scad

@@ -18,6 +18,11 @@ OFFSET=0.01;
 module boxProfileUS( length ,height=23, tabHeight = 8,tabLength = 20, backRounding = 8, backExtra = 10 ) {
 
 
+    echo ("------ height",height);
+    echo ("------ tabHeight",tabHeight);
+    echo ("------ height-tabHeight",height-tabHeight);    
+    assert (height-tabHeight,"height-tabHeight should be bigger than 0");
+    
     tabExtra = opp_ang_to_adj(height-tabHeight,45);
     points = [
         [ -tabLength                    , 0             ,1],            // 0
@@ -58,12 +63,15 @@ 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 ) {
+module usBoxMold( length, height=23, thickness = 9, moldThickness = 4,tabLength = 20,part = "bottom",skirtAngle=80 , skirt = true ) {
 
 //assert(length == 130,"Not 130");
+    assert (length >0,"length should be bigger than 0");
 
     moldHeight = thickness + 2 * moldThickness;
     skirtHeight = 3 * thickness;
+    echo ("---skirtHeight",skirtHeight);
+    echo ("---part",part);
     deviation = opp_ang_to_adj (skirtHeight,skirtAngle);    // Skirt devitation
     
     baseInt = profileUS (length);
@@ -75,11 +83,20 @@ module usBoxMold( length, height=23, thickness = 9, moldThickness = 4,tabLength
         difference() {
             // Mold
             {
-                if ( part == "bottom")
+                //if ( part == "bottom")
+                    
                     down (moldHeight/2) linear_extrude(moldHeight)    
                         offset(r=moldThickness) 
                             boxProfileUS( length, height );
-                if ( part == "top") {
+
+                /*                        
+                if ( part == "top")
+                    
+                    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);
@@ -98,6 +115,8 @@ module usBoxMold( length, height=23, thickness = 9, moldThickness = 4,tabLength
                     */        
                 }                    
             }        
+            
+            
             // US Box to subtract
             usBox(length,height,drill=false,color="Red");
 
@@ -110,14 +129,12 @@ module usBoxMold( length, height=23, thickness = 9, moldThickness = 4,tabLength
                 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 (skirt) difference(){
-            if (showSkirt) difference(){
                 skin([baseExt,topExt],z=[0,skirtHeight],slices=0);
                 skin([baseInt,topInt],z=[0,skirtHeight+OFFSET],slices=0);
             }
@@ -129,11 +146,16 @@ module usBoxMold( length, height=23, thickness = 9, moldThickness = 4,tabLength
     
 }
 
-module finBoxMold( length, finLength=-1, skirtAngle = 80, part="bottom") {
+//usBoxMold (130,part="bottom",skirt=false);
+
+//back (30) usBoxMold (130,part="top",skirt=false);
+
+
+module finBoxMold( length, finLength=-1, skirtAngle = 80, part="bottom", skirt = true) {
 
     assert (finLength,"Missing 'finLength' parameter in finBoxMold module");
     //if (part=="bottom") {
-    usBoxMold( length,part=part,skirtAngle=skirtAngle );
+    usBoxMold( length,part=part,skirtAngle=skirtAngle,skirt=skirt );
     //}
     
 }
@@ -166,6 +188,6 @@ module thickness_cut(thickness,height) {
 
 
 
-//down(50) usBoxMold( 130,part="bottom" );
+if (false )down(50) usBoxMold( 130,part="bottom",skirt=false );