optimizing rail-laser (v2)

rail-laser/rail-laser.scad

@@ -4,7 +4,7 @@ $fn = 50;
 
 bodies_gap = 0.05;
 
-laser_dia = 6.5;
+laser_dia = 6.5 + 0.2;
 laser_len = 14.0;
 
 bat_width = 18.0;
@@ -24,7 +24,7 @@ body_width = 25.0;
 body_length = 50.0;
 body_height = 42.0;
 body_frame_offset = 2.5;
-body_frame_gap = 0.5;
+body_frame_gap = 0.2;
 body_cube_rounding = 1.0;
 body_bat_off = 5.5;
 body_switch_off_x = bat_height + 6.0;
@@ -46,10 +46,10 @@ rail_lip_height = 1.0;
 rail_lock_width = 20.0;
 rail_lock_depth = 10.0;
 rail_lock_base_height = 3.0;
-rail_lock_pin_size = 5.0;
-rail_lock_pin_width = 10.0;
+rail_lock_pin_size = 5.23 - 0.1;
+rail_lock_pin_width = 12.0;
 rail_lock_pin_height = 5.0;
-rail_lock_tab_len = 1.0;
+rail_lock_tab_len = 0.5;
 rail_lock_tab_depth = 2.0;
 rail_lock_whole_width = body_width + (2 * rail_lock_tab_len);
 rail_lock_tab_width = (rail_lock_whole_width - rail_lock_width) / 2;
@@ -59,23 +59,28 @@ rail_lock_spring_hole = 1.0;
 
 frame_gap = 0.25;
 frame_sphere = 20;
-frame_add_touch = 4.0;
+frame_add_touch = 3.0;
 frame_wall = 1.5;
-frame_mount_hole = 3.0;
-frame_mount_hole_off = 6.0;
+frame_mount_hole = 2.85;
+frame_mount_hole_off_1 = 3.0;
+frame_mount_hole_off_2 = 8.0;
 frame_mid_len = (frame_mount_hole / 4) + (2 * frame_wall);
-frame_mid_dia = laser_dia + (2 * frame_wall);
+frame_mid_dia = 8; //laser_dia + (2 * frame_wall);
 frame_tail_len = 8.0;
-frame_tail_width = frame_mid_dia + 0.5;
+frame_tail_len_add = 1.0;
+frame_tail_width = 5.5; //frame_mid_dia + 0.5;
 frame_negative_width = frame_sphere * 2 / 3 + 7;
-frame_hole_dia = 2.9;
-frame_hole_dia_arch = 3.3;
+frame_hole_dia = 2.85;
+frame_hole_dia_arch = 3.0 + 0.1;
 frame_hole_off = 1.8;
 frame_hole_neg_off = 10;
 frame_hole_neg_len = 15;
 frame_hole_neg_deg_a = 9;
 frame_hole_neg_deg_b = frame_hole_neg_deg_a;
 
+frame_brim_height = 0.5;
+frame_brim_width = 20.0;
+
 frame_hole_neg_rad_small = frame_mid_len + ((frame_sphere + frame_tail_len) / 2) - frame_hole_off;
 frame_hole_neg_rad_large = frame_mid_len + ((frame_sphere + frame_tail_len) / 2) + frame_hole_off;
 frame_len = frame_sphere + frame_mid_len + frame_tail_len;
@@ -83,12 +88,15 @@ frame_len = frame_sphere + frame_mid_len + frame_tail_len;
 //body_frame_off = body_height - rail_height - (frame_sphere / 2) - body_frame_offset;
 body_frame_off = (frame_sphere / 2) + body_frame_offset;
 
+laser_preview_angle_x = -10 + (20 * $t);
+laser_preview_angle_y = -10 + (20 * $t);
+
 module rail_lip(l) {
     hull() {
-        translate([-1, -0.001, 0])
+        translate([-1, -0.01, 0])
         cube([l + 2, 0.2, rail_lip_width_big]);
-        translate([-1, rail_lip_height - 0.001, (rail_lip_width_big - rail_lip_width_small) / 2])
-        cube([l + 2, 0.001, rail_lip_width_small]);
+        translate([-1, rail_lip_height - 0.01, (rail_lip_width_big - rail_lip_width_small) / 2])
+        cube([l + 2, 0.01, rail_lip_width_small]);
     }
 }
 
@@ -117,7 +125,7 @@ module rail_lock_internal(add = 0.0) {
         cube([rail_lock_tab_width + add, rail_lock_tab_depth + add, rail_lock_base_height + add], center = true);
     } else {
         translate([0, 0, -rail_lock_travel / 2]) {
-            cube([rail_lock_width + add + 0.001, rail_lock_depth + add, rail_lock_base_height + add + rail_lock_travel + 0.001], center = true);
+            cube([rail_lock_width + add + 0.01, rail_lock_depth + add, rail_lock_base_height + add + rail_lock_travel + 0.01], center = true);
         
             translate([(rail_lock_width + add + rail_lock_tab_width + add) / 2, 0, 0])
             cube([rail_lock_tab_width + add, rail_lock_tab_depth + add, rail_lock_base_height + add + rail_lock_travel], center = true);
@@ -171,13 +179,22 @@ module laser_frame(added_gap = 0, negative = 0) {
             sphere(d = frame_sphere + added_gap);
             
             if (negative == 0) {
+                %translate([0, 0, frame_len - frame_sphere / 2])
+                cylinder(d = 0.5, h = 50);
+                
                 // mid section
                 translate([0, 0, frame_len - frame_sphere - frame_mid_len - 0.5])
-                cylinder(d = frame_mid_dia + added_gap, h = frame_mid_len + frame_add_touch + 1.0);
+                hull() {
+                    translate([-(frame_tail_width + added_gap) / 2, -(frame_tail_width + added_gap) / 2, 0])
+                    cube([frame_tail_width + added_gap, frame_tail_width + added_gap, frame_tail_len]);
+                    
+                    translate([0, 0, frame_mid_len + frame_add_touch])
+                    cylinder(d = frame_mid_dia + added_gap, h = 1.0);
+                }
                 
                 // bottom cube
-                translate([-(frame_tail_width + added_gap) / 2, -(frame_tail_width + added_gap) / 2, frame_len - frame_sphere - frame_mid_len - frame_tail_len]) {
-                    cube([frame_tail_width + added_gap, frame_tail_width + added_gap, frame_tail_len]);
+                translate([-(frame_tail_width + added_gap) / 2, -(frame_tail_width + added_gap) / 2, frame_len - frame_sphere - frame_mid_len - frame_tail_len - frame_tail_len_add]) {
+                    cube([frame_tail_width + added_gap, frame_tail_width + added_gap, frame_tail_len + frame_tail_len_add]);
                     //roundedcube([frame_tail_width + added_gap, frame_tail_width + added_gap, frame_tail_len]);
                 }
             } else {
@@ -199,17 +216,30 @@ module laser_frame(added_gap = 0, negative = 0) {
         
         if (negative == 0) {
             // cutout for laser itself
-            translate([0, 0, -1])
-            cylinder(d = laser_dia + (2 * frame_gap), h = frame_len + 2);
+            translate([0, 0, frame_len - frame_sphere + 1])
+            cylinder(d = laser_dia + (2 * frame_gap), h = frame_sphere);
         
             // holding screws for laser
-            translate([0, 0, frame_len - (frame_mount_hole / 2) - frame_mount_hole_off])
+            translate([0, 0, frame_len - (frame_mount_hole / 2) - frame_mount_hole_off_1])
             rotate([0, 90, 45]) {
                 cylinder(d = frame_mount_hole, h = frame_sphere);
             
                 rotate([-90, 0, 0])
                 cylinder(d = frame_mount_hole, h = frame_sphere);
             }
+            translate([0, 0, frame_len - (frame_mount_hole / 2) - frame_mount_hole_off_2])
+            rotate([0, 90, 45]) {
+                cylinder(d = frame_mount_hole, h = frame_sphere);
+            
+                rotate([-90, 0, 0])
+                cylinder(d = frame_mount_hole, h = frame_sphere);
+            }
+            
+            // cable cutout for laser
+            //rotate([0, 0, -90])
+            translate([0, 5, 6.5])
+            rotate([30, 0, 0])
+            cylinder(d = 2.5, h = 10);
             
             // x-axis holes
             translate([-frame_tail_width / 2 - 1, 0, frame_len - frame_sphere - frame_mid_len - frame_tail_len + (frame_tail_len / 2) - frame_hole_off])
@@ -237,9 +267,9 @@ module switch(add = 0.0) {
     cube([switch_nub, switch_nub, switch_nub]);
     
     translate([(switch_length - switch_length_body) / 4, switch_width / 2, 0]) {
-        cylinder(d = switch_hole_dia, h = switch_height + (switch_nub * 4));
+        cylinder(d = switch_hole_dia, h = switch_height + 1);
         translate([switch_hole_dist, 0, 0])
-        cylinder(d = switch_hole_dia, h = switch_height + (switch_nub * 4));
+        cylinder(d = switch_hole_dia, h = switch_height + 1);
     }
 }
 
@@ -250,13 +280,17 @@ module body(hole_dia) {
         //roundedcube([body_length, body_width, body_height], false, body_cube_rounding);
         
         // cutout for rail
-        translate([-1, (body_width - rail_width) / 2, body_height - rail_height + 0.001])
+        translate([-1, (body_width - rail_width) / 2, body_height - rail_height + 0.01])
         rail(body_length + 2);
         
         // cutout and preview for laser frame
         translate([body_length - frame_len, body_width / 2, body_frame_off])
         rotate([0, 90, 0]) {
             laser_frame(body_frame_gap, 1);
+            
+            translate([0, 0, frame_len - frame_sphere / 2])
+            rotate([laser_preview_angle_x, laser_preview_angle_y, 180])
+            translate([0, 0, -(frame_len - frame_sphere / 2)])
             %laser_frame();
         }
         
@@ -267,7 +301,7 @@ module body(hole_dia) {
         }
         
         // cutout and preview for switch
-        translate([body_switch_off_x, body_width - switch_height + 0.001, body_height - rail_height - body_switch_off_y])
+        translate([body_switch_off_x, body_width - switch_height + 0.01, body_height - rail_height - body_switch_off_y])
         rotate([-90, 0, 0]) {
             switch(body_switch_add);
             %switch(0);
@@ -275,14 +309,16 @@ module body(hole_dia) {
             // cutout for cabling
             // TODO not very nice,
             // with hardcoded values
-            translate([-0.001, -2.5, -8])
+            translate([-0.01, -2.5, -8])
             cube([18.5, 30, 9.5]);
         }
         
         // cutout and preview for rail locking mechanism
         translate([body_length - body_rail_lock_off_x, body_width / 2, rail_lock_base_height / 2 + body_height - rail_height - body_rail_lock_off_z])
-        rotate([0, 0, 90]) {
+        rotate([0, 0, -90]) {
             rail_lock(0.5);
+            
+            translate([0, 0, -(rail_lock_travel * $t)])
             %rail_lock();
         }
         
@@ -330,8 +366,13 @@ module print() {
     rotate([90, 0, 0])
     body_half(1);
     
-    translate([body_length + 10, body_height + 2, 0])
-    laser_frame(0, 0);
+    translate([body_length + (frame_brim_width / 2) + 5, body_height + (frame_brim_width / 2) + 5, 0]) {
+        translate([0, 0, frame_tail_len_add])
+        laser_frame(0, 0);
+        
+        translate([0, 0, frame_brim_height / 2])
+        cube([frame_brim_width, frame_brim_width, frame_brim_height], center = true);
+    }
     
     translate([body_length + 10, 20, rail_lock_base_height / 2])
     rotate([0, 0, 90])
@@ -343,9 +384,9 @@ module print() {
 }
 
 //laser_frame();
-rail_lock();
+//rail_lock();
 
 //body_half(0);
 //body_half(1);
 
-//print();
+print();