Holes

Kitesurf-Fins.json

@@ -5,7 +5,7 @@
             "$fn": "64",
             "base_extra_thickness": "20",
             "base_tickness": "8",
-            "draw_fin": "true",
+            "build_fin": "true",
             "draw_profile": "false",
             "fin_back_angle": "20",
             "fin_back_height": "30",
@@ -28,13 +28,15 @@
             "fin_width_tip": "5",
             "parts": "all",
             "scale_factor": "1",
-            "show_debug_layers": "true"
+            "show_debug_layers": "false"
         },
         "New set 2": {
             "$fn": "64",
+            "OFFSET": "0.01",
             "base_extra_thickness": "20",
             "base_tickness": "8",
-            "draw_fin": "false",
+            "build_fin": "true",
+            "build_mold": "true",
             "draw_profile": "false",
             "fin_back_angle": "20",
             "fin_back_height": "30",
@@ -55,36 +57,15 @@
             "fin_top_withdraw": "10",
             "fin_width": "120",
             "fin_width_tip": "5",
-            "parts": "all",
-            "scale_factor": "1",
-            "show_debug_layers": "false"
-        },
-        "New set 3": {
-            "$fn": "64",
-            "base_extra_thickness": "20",
-            "base_tickness": "8",
-            "draw_fin": "false",
-            "draw_profile": "true",
-            "fin_back_angle": "20",
-            "fin_back_height": "30",
-            "fin_back_strength": "30",
-            "fin_back_widthdraw": "20",
-            "fin_back_withraw": "20",
-            "fin_base": "114",
-            "fin_counter_angle": "30",
-            "fin_counter_strength": "10",
-            "fin_edge_angle": "30",
-            "fin_edge_strength": "30",
-            "fin_end_angle": "110",
-            "fin_end_strength": "30",
-            "fin_height": "51",
-            "fin_start_angle": "60",
-            "fin_sweep": "25",
-            "fin_thickness": "8",
-            "fin_top_withdraw": "10",
-            "fin_width": "120",
-            "fin_width_tip": "5",
-            "parts": "all",
+            "merge_holes_diameter": "6",
+            "mold_base_height": "10",
+            "mold_extra_width": "15",
+            "mold_part": "bottom",
+            "mold_piston_height": "10",
+            "mold_top_height": "6",
+            "parts": "bottom",
+            "piston_depth": "5",
+            "resin_escape_diameter": "4",
             "scale_factor": "1",
             "show_debug_layers": "false"
         }

Kitesurf-Fins.scad

@@ -3,11 +3,12 @@ include <BOSL2/std.scad>;
 include <BOSL2/beziers.scad>;
 include <BOSL2/rounding.scad>;
 include <BOSL2/skin.scad>;
+include <BOSL2/threading.scad>;
 
 include <DotScad/src/bend.scad>;
 include <DotScad/src/bend_extrude.scad>;
 include <DotScad/src/ellipse_extrude.scad>;
-include <DotScad/src/rounded_extrude.scad>;
+include <DotScad/src/loft.scad>;
 
 /************************************************/
 /*  Parameters                                  */
@@ -50,49 +51,86 @@ fin_back_strength=30;
 base_tickness=8; 
 base_extra_thickness=20;
 
-
 /* [Debugging] */
 
 // Showing all layers
 show_debug_layers = false;
 
 // Draw master profile
-draw_profile = true;
+draw_profile = false;
 
 // Draw Fin
-draw_fin = false;
+build_fin = false;
+
+// Build mold
+build_mold = true;
+
+/* [Mold] */
+
+// Mold base height
+mold_base_height = 10;
+mold_top_height = 5;
+mold_extra_width = 15;
+
+mold_piston_height = 10;
+
+resin_escape_diameter=4; 
+
+// Diameter for screw holes in mm
+merge_holes_diameter = 6;
+piston_depth = 5;
 
 /* [Rendering] */
 
 // Rendering parts
 parts           = "all";      // [all, top, bottom]
 
+mold_part       = "all";   // [all, top, bottom]
 // Scaling
 scale_factor    = 1.0; // [0.1:0.1:2] 
 
+// Printable rendering
+printable       = true;
+
+// Rendering mold
+//render_mold = true;
+
 
 $fn=64;
+
+/*************/
+/* Constants */
+/*************/
+
+
+// Define the offset value as a constant
+OFFSET = 0.01;
+
 /************************************************/
+/* Derived variable */
+
+mold_width  = fin_height +2 * mold_extra_width;
+mold_length = fin_width  +2 * mold_extra_width;
+mold_height = mold_base_height;
+
+drilling_length = mold_base_height+mold_piston_height+2*OFFSET;
 
 
 pt1_x = adj_ang_to_opp(fin_height,fin_sweep)+fin_base/2;
 pt1_y = fin_height;
 
-echo ("counterTop(fin_width,fin_top_withdraw)",counterTop(fin_width,fin_top_withdraw,fin_height));
-
-echo ("handleEnd(fin_width,fin_top_withdraw,fin_counter_angle,fin_counter_strength)",handleEnd(fin_width,fin_top_withdraw,fin_counter_angle,fin_counter_strength));
-echo ("xAngleFactor(-20)",xAngleFactor(-20));
-
-echo("polar_to_x : ",polar_to_xy(100, 180));
-
-back_point = [fin_width-7,fin_height/2];
+//back_point = [fin_width-7,fin_height/2];
 tail_point = [fin_width-3,fin_height/5];
 
 edge_point = [fin_width-fin_top_withdraw,fin_height-2];
 counter_edge_point = [fin_width-6,fin_height-8];
 
 
-control_points = [
+
+/******************/
+/* Profile points */
+/******************/
+ profile_points = [
     // *****************
     //   INITIAL POINT
     // *****************    
@@ -107,219 +145,33 @@ control_points = [
     // *****************
     //   EDGE POINT
     // *****************
-    //counterTop(fin_width,fin_top_withdraw,fin_height), // [250,220],   // Point 2
-    handle(edge_point,140 /*degree*/,4),
-    edge_point, // [250,220],   // Point 2
-    handle(edge_point,-45 /*degree*/,4),
+    handle(edge_point,140 ,4),
+    edge_point,                                                     // Point Edge Point
+    handle(edge_point,-45,4),
     // *****************
     //   COUNTER EDGE POINT
     // *****************
-    //counterTop(fin_width,fin_top_withdraw,fin_height), // [250,220],   // Point 2
-    handle(counter_edge_point,120 /*degree*/,4),
-    counter_edge_point, // [250,220],   // Point 2
-    handle(counter_edge_point,-110 /*degree*/,13),    
-
-    // *****************
-    //   BACK Point
-    // *****************
-    //counterTop(fin_width,fin_top_withdraw,fin_height), // [250,220],   // Point 2
-    /*
-    handle(back_point,90 ,6),
-    back_point,
-    handle(back_point,-90 ,6),
-    */
-
+    handle(counter_edge_point,120,4),
+    counter_edge_point,                                             // Point Counter Edge
+    handle(counter_edge_point,-110,13),    
     // *****************
     //   TAIL Point
     // *****************
-    
     handle(tail_point,115 ,10),
     tail_point,
-    //handle(tail_point,-90,10),    
     handle(tail_point,0,0),    
-    //tailPoint(),
-    // *****************
-    //   BACK POINT
-    // *****************
-    /*
-    handle(backPoint(),fin_back_angle,fin_back_strength),
-    backPoint(),
-    handle(backPoint(),-fin_back_angle,fin_back_strength),
-    */
     // *****************
     //   END POINT
     // *****************
-    //endHandle(fin_end_angle),                                       // End Handle
-    handle([fin_base,0],60 /*degree*/,3),
+    handle([fin_base,0],60,3),
     [fin_base,0]                                                    // End point
 ];
 
-
-top_point = [0,fin_height];
-p1 = [fin_thickness/2,0];
-p2 = [-fin_thickness/2,0];
-
-
-vertical_shape=[
-    p1,
-    handle(p1,90,fin_height/1.2),
-    // *****************
-    //   TOP Point
-    // *****************      
-    handle(top_point,140 /*degree*/,0),
-    top_point,
-    handle(top_point,140 /*degree*/,0),
-    // *****************
-    //   END POINT
-    // *****************    
-    handle(p2,90,fin_height/1.2),
-    p2
-];
-
-lpoint=[fin_width/2,0];
-rpoint=[-lpoint[0],0];
-top_strength=fin_width/8;
-
-top_shape=[
-    // Right
-    rpoint,
-    handle(rpoint,150,top_strength),
-    // Left
-    handle(lpoint,40,top_strength),
-    lpoint,
-    handle(lpoint,-40,top_strength),
-    // Final
-    handle(rpoint,-150,top_strength),
-    rpoint
-];
-
-// Calculate points along the Bézier curve. 
-// 'N' here determines the number of points to calculate.
-//N = 50; // Number of points to generate
-profile_path    = asCurve(control_points);
-vertical_path   = asCurve(vertical_shape);
-top_path        = asCurve(top_shape);
-
-echo ("vertical_path",vertical_path);
-
-left(50) polygon(vertical_path);
-left(180) polygon(profile_path);
-//left(280) polygon(top_path);
-
-left(100) back(70)
-resize([fin_width,fin_thickness])circle(d=fin_width);
-
-
-//showDebugPath(top_path);
-
-
-function asCurve(points) = bezier_curve(points,N=3,splinesteps=128);
+profile_path  = translate_path( asCurve(profile_points),-fin_width/2 );
                   
                   
                   
-
-
-/*
-bezier = bezier_points(control_points, N=50);
-
-// Convert the Bézier curve points to a 3D path starting at z=0
-path3d_bezier = path3d(bezier);
-*/
-intersection(){
-    if (true) down(fin_thickness) linear_extrude(height=fin_thickness*2) {
-        polygon(profile_path);
-    };
-    left(0) yrot(90) linear_extrude(height=fin_width) {
-        polygon(vertical_path);
-    };   
-    if (true) right(fin_width/2) xrot(-90) linear_extrude(height=fin_height) {
-        resize([fin_width,fin_thickness])circle(d=fin_width); 
-    };  
- 
-}
-
-color("Red") left(300) intersection(){
-    left(0) yrot(90) 
-   
-    //bend(size = [fin_width*3, fin_height*2, fin_tickness*4], angle = 270) 
-        linear_extrude(height=fin_width) 
-            polygon(vertical_path);
-    if (true) right(fin_width/2) xrot(-90) linear_extrude(height=fin_height) {
-        resize([fin_width,fin_thickness])circle(d=fin_width); 
-    };  
-
-}
-   
- color("green") left(300) back(70)
-    left(0) yrot(90) 
-    //bend(size = [fin_width*3, fin_height*2, fin_tickness*4], angle = 30) 
-        linear_extrude(height=fin_width) 
-        //bend_extrude(size = [100, 100], thickness = 1, angle = 270)
-            polygon(vertical_path);
-            //text("A");
-        ;   
-
-path = [for(theta=[-180:5:180]) [theta/10, 10*sin(theta)]];    
-
-
-// https://github.com/BelfrySCAD/BOSL2/wiki/skin.scad#functionmodule-path_sweep    
-color("Yellow") path_sweep(
-    vertical_path,
-    get_n_items(profile_path,80),
-    spin=0
-    );
-
-    
- semi_minor_axis = 2;
- 
- echo ("PATH LENGTH",len(profile_path));
- echo ("PATH LENGTH2",len(subdivide_path(profile_path,400)));
- echo ("PATH LENGTH3",len(resample_path(profile_path,500)));
- 
- print_path_points(profile_path);
- 
-print_path_points(translate_path(profile_path,-fin_width/2,0));
-
- if (true) color("Brown") left(200) back(155) down(fin_thickness) 
-    ellipse_extrude(
-        //semi_minor_axis, 
-        fin_thickness/2,
-        //height = 16,
-        center=true,
-        //convexity=40
-        //angle=90
-        ) 
-    //linear_extrude(height=fin_thickness*2) 
-    //linear_extrude(height=60) 
-        polygon(
-            translate_path( 
-                resample_path(profile_path,200),
-                -fin_width/2,
-                0
-            )
-        );
-    
-
-circle_r = 10;
-round_r = 5;
-    
-right(200) rounded_extrude(circle_r * 2, round_r) 
-    circle(circle_r);
-    
-right(300) rounded_extrude(circle_r * 2, round_r) 
-    polygon(resample_path(profile_path,200));
-
-
-color("red")move_copies(profile_path) circle($fn=16);
-
-    
-    
-   
-
-function get_n_items(arr, n) = 
-    [for (i = [0 : n - 1]) if (i < len(arr)) arr[i]];
-
-
+function asCurve(points) = bezier_curve(points/*,N=3*/,splinesteps=128);
 function handle(point,angle,strength) = [
     //point[0] + adj_ang_to_opp(strength,angle)   /** xAngleFactor(angle)*/,
     //point[1] + /*(angle>0 ? strength :-strength)*/ strength  * yAngleFactor(angle),
@@ -330,7 +182,7 @@ function handle(point,angle,strength) = [
 function xAngleFactor(angle) = angle > 0 && angle < 180 ? 1 : -1;
 function yAngleFactor(angle) = angle > -90 && angle < 90 ? 1 : -1;
 
-function counterTop(x,withdraw,height)                 = [x-withdraw, height ];
+//function counterTop(x,withdraw,height)                 = [x-withdraw, height ];
 function handleStart(x,withdraw,angle,strength) = [x+adj_ang_to_opp(strength,angle), x-withdraw +strength];
 function handleEnd(x,withdraw,angle,strength)   = [x-adj_ang_to_opp(strength,angle), x-withdraw -strength];
 function endHandle(angle)= 
@@ -339,75 +191,233 @@ function endHandle(angle)=
         : 
         [fin_base - adj_ang_to_opp(fin_end_strength,angle-90),fin_end_strength] 
         ;
-function backPoint() = [fin_base-(fin_back_widthdraw/100*fin_base),fin_back_height/100*fin_height];
-
-
 
+//function backPoint() = [fin_base-(fin_back_widthdraw/100*fin_base),fin_back_height/100*fin_height];
 
 function decrease_y(points, percentage) = [ for (p = points) [p[0], p[1] * (1 - percentage/100)]];
 
 function pathProfile(points) = bezpath_curve(points,N=3);
 
-function remove_last(arr) = select(arr, 0, len(arr) - 2);
-
-
 // Surf Fin profile
-fin_profile = pathProfile( control_points );
-vertical_profile = pathProfile(vertical_shape);
+fin_profile         = pathProfile( profile_points );
 
-// ****************
-// *  Slicing     *
-// ****************
-
-layer_0 = pathProcess(addBase(fin_profile));                     // Master layer with base
-layer_1 = contract(layer_0,-5);
-layer_2 = contract(layer_1,-4);
-layer_3 = contract(layer_2,-4);
-layer_4 = contract(layer_3,-2);
-
-//echo ("layer_2",layer_2);
-//echo ("layer_3",layer_3);
-
-
-//layers = [layer_0,layer_1,layer_2,layer_3,layer_4];
-layers = [layer_0,layer_1,layer_2,layer_3];
-
-
-
-function pathProcess2(path) = subdivide_path(path,100);
-function pathProcess(path) = path;
-function contract2(path,delta) = pathProcess(offset(path,r=delta,chamfer=true));
-function contract(path,delta) = 
-    pathProcess(
+function expandPath(path,delta) = 
         offset(
             deduplicate(path),
             delta=delta,
             chamfer=false,
             same_length=true
        )
-    );
+    ;
     
     
-
-
-
-// ****************
+// *****************
 // *  Fin Drawing  *
-// ****************
-if (draw_fin) {
-
-    scale([scale_factor, scale_factor, scale_factor]) build();
+// *****************
+if (build_fin) {
+    scale([scale_factor, scale_factor, scale_factor]) buildFin();
 }
 
-module build() {
+if (build_mold) {
+   buildMold();    
+}
+
+/**
+ * Build mold
+ * 
+ */
+module buildMold() {
+    // Bottom mold
+    difference() { 
+        case(mold_base_height,true);
+        // Piston
+        down(piston_depth-OFFSET) fwd(20) bottomInsert(); 
+    }
+    // Top Mold
+    up(printable ? 0 : 60) fwd(printable ? fin_height+50 : 0) down(mold_base_height) mirror([0,0,printable ? 1 : 0 ])  {
+    
+    
+        difference() {
+            union() {
+                // case
+                case(mold_top_height,false); 
+
+                // Piston
+                mirror([1,0,0])        
+                down(mold_top_height+piston_depth-OFFSET) fwd(20) topPiston(); 
+            };
+            resin_escape(40);
+        
+        };
+       
+    };         
+}
+
+/**
+ * Mold Case 
+ *
+ * @param height - Height of the case
+ * @param bottom - Is bottom or top 
+ */
+module case_old(height,bottom=true) {
+    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   
+/*        
+        align(TOP,[CENTER+BACK+LEFT],inside=true,inset=15,overlap=-OFFSET) 
+                color("Red") wedge([mold_height+2*OFFSET, 50, 30], center=true,orient=FRONT,spin=-90        );                        
+  */              
+        // Material holes
+        align(TOP,[CENTER+BACK+LEFT]/*,inside=true*/,inset=15,overlap=-OFFSET) 
+            color("Red")
+                up(OFFSET)
+                    tag("remove") 
+                        rounded_triangle(radius=3, height=height+2*OFFSET);                    
+    }             
+}
+
+
+
+
+
+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   
+    /*        
+            align(TOP,[CENTER+BACK+LEFT],inside=true,inset=15,overlap=-OFFSET) 
+                    color("Red") wedge([mold_height+2*OFFSET, 50, 30], center=true,orient=FRONT,spin=-90        );                        
+      */              
+            
+                          
+        };
+        // Material holes
+        mirror([bottom ? 0:1,0,0])
+        back(38) left(55)
+                color("Red")
+                    up(OFFSET)
+                        //tag("remove") 
+                            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);
+        
+   }
+}
+
+module rounded_triangle(radius, height) {
+    triangle_points = [[0, 0], [75, 0], [0, -35]]; // Equilateral triangle with side length 100
+    // Round the corners of the triangle
+    rounded_shape = round_corners( triangle_points, r=radius );
+    // Extrude the 2D rounded triangle
+    //mirror([0,0,1]) linear_extrude(height = height) polygon(rounded_shape);
+    mirror([0,0,1]) linear_extrude(height = height) polygon(rounded_shape);
+
+    //mirror([0,0,1]) linear_extrude(height = height) polygon(round_corners(right_triangle([40,30]),r=radius));    
+    //mirror([0,0,1]) linear_extrude(height = height) polygon(right_triangle([40,30]));
+    //mirror([0,0,1]) cyl(l=80, r=10); // Work with cylinder
+}
+
+
+
+// *****************
+// * Bottom insert *
+// *****************
+module bottomInsert() {
+    debug=true;
+    //layer_profile       = pathProcess(profile_path); 
+    layer_profile       = profile_path; 
+    skin( [ layer_profile,expandPath(layer_profile,3) ], z=[0,piston_depth], slices=0 )
+        //up(debug ? 2 : 0)
+       up(OFFSET) 
+        buildFinSide(true)
+        ;
+}
+
+// *****************
+// * Top piston    *
+// *****************
+module topPiston() {
+    debug=true;
+    layer_profile       = profile_path; 
+    difference() {
+        skin( [ layer_profile,expandPath(layer_profile,3) ], z=[0,piston_depth], slices=0 );
+        down(OFFSET)
+        buildFinSide(false);
+    }
+}
+
+
+/**
+ * Build fin side
+ * 
+ * @param flip - Define it it is top or bottom fin side
+ */
+module buildFinSide(flip=false) {
+    debug=false;
+    mirror([0,0,flip ? 1 : 0])
+        color(flip ? "Gray" : "LightGray") /*up(fin_thickness/4)*/ /*down(fin_thickness) */
+        ellipse_extrude( fin_thickness/2*(debug?1.2:1)) 
+            polygon(profile_path);
+} 
+
+module resin_escape(length) {
+    color ("Blue") cylinder(h=length, r=resin_escape_diameter/2);
+}
+
+// *****************
+// *  Drilling     *
+// *****************
+module drilling(){
+
+//length = mold_base_height+mold_piston_height+10;
+
+/*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
+
+    );
+}
+
+
+
+
+//drilling();
+
+module buildFin() {
+    if (false)
     union(){
         difference(){
             union() {
                 if (parts !=  "bottom") 
-                    buildFinSide([layer_0,layer_1,layer_2],fin_thickness/2);
+                    //buildFinSide([layer_0,layer_1,layer_2],fin_thickness/2);
+                    buildFinSide();
                 if (parts !=  "top")
-                    zflip() 
-                        buildFinSide([layer_0,layer_1,layer_2],fin_thickness/2);    
+                    buildFinSide(true);
+                    //zflip() 
+                    //    buildFinSide([layer_0,layer_1,layer_2],fin_thickness/2);    
             }
             color("Red") cube([fin_base+20,base_extra_thickness+20,base_tickness+20],anchor=LEFT+BACK);
         }
@@ -420,29 +430,8 @@ module subtracted(anchor) {
 }
 
 
-/**
- * Build fin side
- * 
- * @param layers - Layers path as array
- * @param thickness - thickness of half fin
- */
-module buildFinSide(layers,thickness,flip=false) {
-    color("Grey") 
-        skin(
-            layers,
-            slices=0,
-            //method="reindex",
-            z=layerHeights(len(layers),thickness),
-            //caps=true,
-            sampling="segment",
-            //closed=false
-            //convexity=40
-            //atype="intersect"
-            cp="box"
-        );
-} 
 
-echo ("layerHeights(3,thickness):",layerHeights(3,base_tickness/2));
+
 
 if (show_debug_layers) {
     left(130) {
@@ -461,7 +450,7 @@ if (show_debug_layers) {
 }
 if (draw_profile) {
     // Draw fin profile
-    drawProfile( control_points, true  );
+    drawProfile( profile_points, true  );
 }
 
 
@@ -516,24 +505,10 @@ module drawProfile( points,debug = true ){
 function addBase(path) = concat(path,[[fin_base,-base_extra_thickness],[0,-base_extra_thickness]]);
 
 
-/**
- * Calculates heights for n layers where the first layer starts at 0 and the last at fin_thickness.
- * 
- * @param n - Number of layers.
- * @param fin_thickness - The total height to be divided.
- * @return An array where each element represents the height of the top of each layer.
- */
-function layerHeights(n, fin_thickness) = 
-    let(
-        layer_height = fin_thickness / (n - 1)
-    )
-    [ for (i = [0 : n-1]) i * layer_height ];
-    
-
 /**
  * Function to translate a path manually along X and Y
  */ 
-function translate_path(path, dx, dy) = 
+function translate_path(path, dx=0, dy=0) = 
     [for (p = path) [p[0] + dx, p[1] + dy]];    
     
     
@@ -548,9 +523,13 @@ module print_path_points(path) {
 echo ("**********************");
 echo ("*  Configuration     *");
 echo ("**********************");
-echo ("Layers count"        ,len(layers));
+//echo ("Layers count"        ,len(layers));
 echo ("Base thickness"      ,str(base_tickness," mm"));
-echo ("Layers heights"      ,layerHeights(len(layers),fin_thickness/2));    
+  
+
+
+
+