xyRepRap/xyRepRap.scad

// #######################################################
// ################## Config Parameters ##################
// #######################################################

slot = 30; // or 20
slot_off = 1; // distance between adjacent slots

// print area / volume
heatbed_width = 400;
heatbed_length = 400;

heatbed_height = 6;

// distance between heatbed edge and inner t-slot frame edge
frame_off_x = 20;
frame_off_y = 20;

outer_width = heatbed_width + (2 * (slot + frame_off_x));
outer_length = heatbed_length + (2 * (slot + frame_off_y));

// TODO depend on print area height
outer_height = 500;

rail_mount_dist = 12;
y_carriage_pos = 175;
x_carriage_pos = 180;

// distance between heatbed and z-carriage frame
bed_x_off = 20;
bed_y_off = 20;
bed_z_dist = 30;

// display heatbed centered in print volume
bed_draw_height = (outer_height - heatbed_height) / 2; // + 175;

show_outer_frame = true;
show_extruders = false;
show_z_motion = true;

show_heatbed_frame = true;
show_heatbed = true;

show_xy_motion = true;
show_x_carriage = false;
show_belts = false;

echo(print_x=heatbed_width, print_y=heatbed_length);
echo(frame_x=outer_width, frame_y=outer_length, frame_z=outer_height);

// #######################################################
// ###################### Libraries ######################
// #######################################################

include <lib/tslot_xy.scad>
include <lib/nema.scad>
include <lib/Belt_Generator.scad>
include <lib/Pulley_T-MXL-XL-HTD-GT2_N-tooth.scad>
include <lib/bearing_idler.scad>
include <lib/rail_mount.scad>
include <lib/linear_bearing.scad>
include <lib/extruder.scad>

module gt2_belt(length) {
    if (show_belts) {
        difference() {
            belting("straight", "GT2_2mm", belt_length = length);
            translate([-5, -5, 6])
                cube([length + 10, 10, 10]);
        }
    }
}

// #######################################################
// ######################## Frame ########################
// #######################################################

module slot_angle_connector() {
    color("gray")
    translate([slot, 0, 0])
    rotate([0, -90, 0])
    difference() {
        cube([slot, slot, slot]);
        translate([0, -5, 0])
            rotate([0, 45, 0])
            cube([2 * slot, 2 * slot, 2 * slot]);
    }
}

module foot() {
    color("yellow")
    translate([0, 0, 10])
        cylinder(d = 6, h = 20);
    
    color("yellow")
    difference() {
        sphere(d = 20);
        translate([-15, -15, -30])
            cube([30, 30, 30]);
    }
}

module lower_frame(double) {
    if (double) {
        translate([slot + slot_off, 0, slot])
            rotate([-90, 0, 0])
            tslot_2_x(slot, outer_width - (2 * (slot + slot_off)));
        
        translate([slot + slot_off, outer_length - slot, slot])
            rotate([-90, 0, 0])
            tslot_2_x(slot, outer_width - (2 * (slot + slot_off)));
        
        translate([0, slot + slot_off, 0])
            tslot_2_y(slot, outer_length - (2 * (slot + slot_off)));
        translate([outer_width - slot, slot + slot_off, 0])
            tslot_2_y(slot, outer_length - (2 * (slot + slot_off)));
    } else {
        translate([slot + slot_off, 0, 0])
            tslot_x(slot, outer_width - (2 * (slot + slot_off)));
        
        translate([slot + slot_off, outer_length - slot, 0])
            tslot_x(slot, outer_width - (2 * (slot + slot_off)));
        
        translate([0, slot + slot_off, 0])
            tslot_y(slot, outer_length - (2 * (slot + slot_off)));
        translate([outer_width - slot, slot + slot_off, 0])
            tslot_y(slot, outer_length - (2 * (slot + slot_off)));
    }
}

module frame() {
    // outer corner pillars
    tslot_z(slot, outer_height);
    translate([outer_width - slot, 0, 0])
        tslot_z(slot, outer_height);
    translate([0, outer_length - slot, 0])
        tslot_z(slot, outer_height);
    translate([outer_width - slot, outer_length - slot, 0])
        tslot_z(slot, outer_height);

    lower_frame(false);
    
    // top frame
    translate([0, 0, outer_height - slot])
        lower_frame(true);
    
    // end caps
    color("black")
    translate([0, 0, outer_height]) {
        cube([slot, slot, 2]);
        translate([outer_width - slot, 0, 0])
            cube([slot, slot, 2]);
        translate([0, outer_length - slot, 0])
            cube([slot, slot, 2]);
        translate([outer_width - slot, outer_length - slot, 0])
            cube([slot, slot, 2]);
    }
    
    // feet
    translate([slot / 2, slot / 2, -30])
        foot();
    translate([outer_width - slot / 2, slot / 2, -30])
        foot();
    translate([slot / 2, outer_length - slot / 2, -30])
        foot();
    translate([outer_width - slot / 2, outer_length - slot / 2, -30])
        foot();
    
    // connecting elements
    translate([slot + slot_off, 0, slot + slot_off])
        slot_angle_connector();
    translate([slot + slot_off, outer_length - slot, slot + slot_off])
        slot_angle_connector();
    translate([slot + slot_off, 0, outer_height - slot - slot_off - slot])
        rotate([0, 90, 0])
        slot_angle_connector();
    translate([slot + slot_off, outer_length - slot, outer_height - slot - slot_off - slot])
        rotate([0, 90, 0])
        slot_angle_connector();
    translate([outer_width - slot - slot_off, 0, slot + slot_off])
        rotate([0, -90, 0])
        slot_angle_connector();
    translate([outer_width - slot - slot_off, outer_length - slot, slot + slot_off])
        rotate([0, -90, 0])
        slot_angle_connector();
    translate([outer_width - slot - slot_off, 0, outer_height - slot - slot_off - slot])
        rotate([0, 180, 0])
        slot_angle_connector();
    translate([outer_width - slot - slot_off, outer_length - slot, outer_height - slot - slot_off - slot])
        rotate([0, 180, 0])
        slot_angle_connector();
    translate([slot, slot + slot_off, slot + slot_off])
        rotate([0, 0, 90])
        slot_angle_connector();
    translate([slot, slot + slot_off, outer_height - slot - slot_off - slot])
        rotate([0, 90, 90])
        slot_angle_connector();
    translate([0, outer_length - slot - slot_off, slot + slot_off])
        rotate([0, 0, -90])
        slot_angle_connector();
    translate([0, outer_length - slot - slot_off, outer_height - slot - slot_off - slot])
        rotate([0, 90, -90])
        slot_angle_connector();
    translate([outer_width, slot + slot_off, slot + slot_off])
        rotate([0, 0, 90])
        slot_angle_connector();
    translate([outer_width, slot + slot_off, outer_height - slot - slot_off - slot])
        rotate([0, 90, 90])
        slot_angle_connector();
    translate([outer_width - slot, outer_length - slot - slot_off, slot + slot_off])
        rotate([0, 0, -90])
        slot_angle_connector();
    translate([outer_width - slot, outer_length - slot - slot_off, outer_height - slot - slot_off - slot])
        rotate([0, 90, -90])
        slot_angle_connector();
    translate([slot + slot_off, slot + slot_off, slot])
        rotate([-90, 0, 0])
        slot_angle_connector();
    translate([outer_width - slot - slot_off, slot + slot_off, slot])
        rotate([-90, 0, 90])
        slot_angle_connector();
    translate([slot + slot_off, outer_length - slot - slot_off, 0])
        rotate([90, 0, 0])
        slot_angle_connector();
    translate([outer_width - slot - slot_off, outer_length - slot - slot_off, 0])
        rotate([90, 0, -90])
        slot_angle_connector();
    /*
    translate([slot + slot_off, slot + slot_off, outer_height])
        rotate([-90, 0, 0])
        slot_angle_connector();
    translate([outer_width - slot - slot_off, slot + slot_off, outer_height])
        rotate([-90, 0, 90])
        slot_angle_connector();
    translate([slot + slot_off, outer_length - slot - slot_off, outer_height - slot])
        rotate([90, 0, 0])
        slot_angle_connector();
    translate([outer_width - slot - slot_off, outer_length - slot - slot_off, outer_height - slot])
        rotate([90, 0, -90])
        slot_angle_connector();
    */
}

// #######################################################
// ###################### Mechanics ######################
// #######################################################

module rail(length) {
    cylinder(d = rail_dia, h = length);
    echo(rail_dia=rail_dia, rail_len=length);
}

module y_rails() {
    // y smooth rail on blue side
    color("cyan")
    translate([rail_dia / 2 + rail_y_off_1, 18, -30])
        rotate([-90, 0, 0])
        rail(outer_length - slot - nema17_size - (2 * rail_mount_dist));
    
    // y carriage on blue side
    translate([rail_y_off_1 - (lm8uu_outer + lm8uu_dia_add) / 2 + y_carriage_rail_support, y_carriage_pos, -slot])
        y_carriage(idler_a_blue, idler_b_blue);
    
    // rail mounts for blue side
    color("green")
    translate([0, 2 * rail_mount_dist, -2 * slot])
        rail_mount(slot);
    color("green")
    translate([0, outer_length - (2 * slot) - nema17_size - rail_mount_dist + 5, -2 * slot])
        rail_mount(slot);
    
    // y smooth rail on red side
    color("cyan")
    translate([outer_width - (2 * slot) - rail_dia / 2 - rail_y_off_1, 18, -30])
        rotate([-90, 0, 0])
        rail(outer_length - slot - nema17_size - (2 * rail_mount_dist));
    
    // y carriage on red side
    translate([outer_width - slot - y_carriage_width - y_carriage_block_width, y_carriage_pos + y_carriage_length, -slot])
        rotate([0, 0, 180])
        y_carriage(idler_a_red, idler_b_red);
    
    // rail mounts for red side
    color("green")
    translate([outer_width - (2 * slot), 2 * rail_mount_dist + rail_mount_len, -2 * slot])
        rotate([0, 0, 180])
        rail_mount(slot);
    color("green")
    translate([outer_width - (2 * slot), outer_length - (2 * slot) - nema17_size - rail_mount_dist + 5 + rail_mount_len, -2 * slot])
        rotate([0, 0, 180])
        rail_mount(slot);
}

module x_rails() {
    // TODO length calculate properly!
    
    color("cyan")
    translate([30, y_carriage_pos, 15])
        rotate([0, 90, 0])
        rail(outer_width - (4 * slot));
    
    color("cyan")
    translate([30, y_carriage_pos + x_rail_dist, 15])
        rotate([0, 90, 0])
        rail(outer_width - (4 * slot));
    
    if (show_x_carriage) {
        translate([x_carriage_pos, y_carriage_pos - x_carriage_len_add, slot / 2])
            x_carriage();
    }
}

module motion_xy() {
    translate([slot, slot, outer_height])
        y_rails();
    
    translate([slot, slot + y_carriage_len_add, outer_height - (1.5 * slot)])
        x_rails();

    // left ("blue") motor
    translate([slot, outer_length - slot - nema17_size - nema17_mount_wall, outer_height + nema17_mount_wall])
    rotate([180, 0, 90]) {
        color("blue")
        translate([0, 0, -65])
            nema17(65);
        
        color("green")
        nema17_mount(slot);
        
        // blue motor pulley
        color("magenta")
        translate([nema17_size / 2, nema17_size / 2, 22.4])
            rotate([180, 0, 0])
            gt2_pulley();
        
        // blue gt2 belt at motor
        color("blue")
        translate([nema17_size / 2, nema17_size / 2 + 6.5, nema17_mount_wall + 1])
        rotate([0, 0, 180])
            gt2_belt(outer_length - (2 * slot) - nema17_size / 2 - x_rail_dist - y_carriage_pos - 15);
        color("blue")
        translate([-outer_length + (3 * slot) + 10 + nema17_size / 2, nema17_size / 2 - 6.5, nema17_mount_wall + 1])
            gt2_belt(outer_length - (3 * slot) - 10);
    }
    
    // right ("red") motor
    translate([outer_width - slot - nema17_size, outer_length - slot - nema17_size - nema17_mount_wall, outer_height + nema17_mount_wall])
    rotate([180, 0, 90]) {
        color("red")
        translate([0, 0, -65])
            nema17(65);
        
        color("green")
        nema17_mount(slot);
        
        // red motor pulley
        color("cyan")
        translate([nema17_size / 2, nema17_size / 2, 8.2])
            gt2_pulley();
        
        // red gt2 belt at motor
        color("red")
        translate([nema17_size / 2, nema17_size / 2 + 6.5, nema17_mount_wall + 8])
        rotate([0, 0, 180])
            gt2_belt(outer_length - (3 * slot) - 10);
        color("red")
        translate([nema17_size / 2 - (outer_length - (2 * slot) - nema17_size / 2 - x_rail_dist - y_carriage_pos - 15), nema17_size / 2 - 6.5, nema17_mount_wall + 8])
            gt2_belt(outer_length - (2 * slot) - nema17_size / 2 - x_rail_dist - y_carriage_pos - 15);
    }
    
    // x carriage belts on blue side
    color("blue")
    translate([slot + 29, slot + x_rail_dist + 7 + y_carriage_pos, outer_height - 1])
        rotate([180, 0, 0])
        gt2_belt(x_carriage_pos - 20);
    color("red")
    translate([slot + 15, slot + 23 + y_carriage_pos, outer_height - 8])
        rotate([180, 0, 0])
        gt2_belt(x_carriage_pos - 6);
    
    // x carriage belts on red side
    color("red")
    translate([slot + x_carriage_width + x_carriage_pos - 7, slot + x_rail_dist + 7 + y_carriage_pos, outer_height - 8])
        rotate([180, 0, 0])
        gt2_belt(outer_width - x_carriage_pos - (2 * slot) - x_carriage_width - 20);
    color("blue")
    translate([slot + x_carriage_width + x_carriage_pos - 7, slot + 23 + y_carriage_pos, outer_height - 1])
        rotate([180, 0, 0])
        gt2_belt(outer_width - x_carriage_pos - (2 * slot) - x_carriage_width - 10);
    
    // long back belts
    color("blue")
    translate([slot + 15, slot + 10, outer_height - 7])
        gt2_belt(outer_width - nema17_size - (2 * slot) + 13);
    color("red")
    translate([slot + 15, slot + 10, outer_height - 14])
        gt2_belt(outer_width - nema17_size - (2 * slot) + 13);
    
    // blue belt on red side
    color("blue")
    translate([outer_width - slot - 15, slot + 10, outer_height - 7])
        rotate([0, 0, 90])
        gt2_belt(y_carriage_pos + 10);
    
    // red belt on blue side
    color("red")
    translate([slot + 15, slot + 19 + y_carriage_pos, outer_height - 14])
        rotate([0, 0, -90])
        gt2_belt(y_carriage_pos + 10);
    
    // idler on blue side
    translate([slot + bearing_mount_width + 15, 0, outer_height - slot])
        rotate([0, 0, 90])
        slot_mount_bracket(slot, true);
        
    // idler on red side
    translate([outer_width - slot - 15, 0, outer_height - slot])
        rotate([0, 0, 90])
        slot_mount_bracket(slot, true);
}

// #######################################################
// ####################### Heatbed #######################
// #######################################################

module heatbed_plate() {
    difference() {
        color("yellow")
        cube([heatbed_width, heatbed_length, heatbed_height]);

        #translate([bed_x_off + (slot / 2), bed_y_off + (slot / 2), -bed_z_dist - slot - 1])
            cylinder(d = 4.2, h = bed_z_dist + slot + heatbed_height + 2);
        #translate([heatbed_width - bed_x_off - (slot / 2), bed_y_off + (slot / 2), -bed_z_dist - slot - 1])
            cylinder(d = 4.2, h = bed_z_dist + slot + heatbed_height + 2);
        #translate([bed_x_off + (slot / 2), heatbed_length - bed_y_off - (slot / 2), -bed_z_dist - slot - 1])
            cylinder(d = 4.2, h = bed_z_dist + slot + heatbed_height + 2);
        #translate([heatbed_width - bed_x_off - (slot / 2), heatbed_length - bed_y_off - (slot / 2), -bed_z_dist - slot - 1])
            cylinder(d = 4.2, h = bed_z_dist + slot + heatbed_height + 2);
    }
    
    echo(max_bed_heater_width=heatbed_width - (2 * bed_x_off) - slot - 5);
    echo(max_bed_heater_length=heatbed_length - (2 * bed_y_off) - slot - 5);
}

module heatbed() {
    translate([slot + frame_off_x, slot + frame_off_y, bed_draw_height]) {
        if (show_heatbed) {
            %heatbed_plate();
        }
        
        // t-slots as heatbed frame
        translate([bed_x_off, bed_y_off, -slot - bed_z_dist])
            tslot_y(slot, heatbed_length - (2 * bed_y_off));
        translate([heatbed_width - slot - bed_x_off, bed_y_off, -slot - bed_z_dist])
            tslot_y(slot, heatbed_length - (2 * bed_y_off));
        translate([slot + bed_x_off + slot_off, bed_y_off, -slot - bed_z_dist])
            tslot_x(slot, heatbed_width - 2 * (bed_x_off + slot + slot_off));
        translate([slot + bed_x_off + slot_off, heatbed_length - slot - bed_y_off, -slot - bed_z_dist])
            tslot_x(slot, heatbed_width - 2 * (bed_x_off + slot + slot_off));
        
        translate([bed_x_off + slot, bed_y_off + slot, -slot - bed_z_dist])
            rotate([90, 0, 90])
            slot_angle_connector();
        translate([bed_x_off + slot, heatbed_length - slot - bed_y_off, -slot - bed_z_dist])
            rotate([90, 0, 0])
            slot_angle_connector();
        translate([heatbed_width - slot - bed_x_off, heatbed_length - slot - bed_y_off, -slot - bed_z_dist])
            rotate([90, 0, -90])
            slot_angle_connector();
        translate([heatbed_width - slot - bed_x_off, bed_y_off + slot, -slot - bed_z_dist])
            rotate([90, 0, 180])
            slot_angle_connector();
    }
}

z_rail_x_off = 60;
z_rail_mount_len = 20;

module motion_z_rail() {
    // bottom clamp
    color("green")
    translate([slot, 0, slot / 2 + 5 + (z_rail_mount_len - rail_mount_len) / 2])
        rotate([-90, 0, 90])
        rail_mount(slot, z_rail_mount_len);
    
    // top clamp
    color("green")
    translate([slot, 0, outer_height - slot / 2 + 5 + (z_rail_mount_len - rail_mount_len) / 2 - slot])
        rotate([-90, 0, 90])
        rail_mount(slot, z_rail_mount_len);
    
    // rail
    color("cyan")
    translate([0, rail_y_off, 4])
        rail(outer_height - slot - 8);
}

z_carriage_wall = 10;

module z_carriage() {
    color("green")
    translate([frame_off_x + bed_x_off - z_rail_x_off, frame_off_y + bed_y_off - rail_y_off, 0]) {
        // bracket on long rail
        translate([-z_carriage_wall, -z_carriage_wall, 0])
            cube([z_carriage_wall, z_carriage_wall + (2 * slot), slot]);
        
        // bracket on short rail
        translate([0, -z_carriage_wall, 0])
            cube([3 * slot, z_carriage_wall, slot]);
    }
    
    // TODO proper long bearings
    color("magenta")
    translate([0, 0, (slot - (2 * lm8uu_height + 1)) / 2]) {
        %lm8uu();
        %translate([0, 0, lm8uu_height + 1])
            lm8uu();
    }
}

module motion_z() {
    // front left
    translate([slot + z_rail_x_off, slot, 0])
        motion_z_rail();
    // front right
    translate([outer_width - z_rail_x_off - slot, slot, 0])
        motion_z_rail();
    // back left
    translate([slot + z_rail_x_off, outer_length - slot, 0])
        rotate([0, 0, 180])
        motion_z_rail();
    // back right
    translate([outer_width - z_rail_x_off - slot, outer_length - slot, 0])
        rotate([0, 0, 180])
        motion_z_rail();
    
    // front left
    translate([slot + z_rail_x_off, slot + rail_y_off, bed_draw_height - bed_z_dist - slot])
        z_carriage();
    // front right
    translate([outer_width - slot - z_rail_x_off, slot + rail_y_off, bed_draw_height - bed_z_dist - slot])
        scale([-1, 1, 1])
        z_carriage();
    // back left
    translate([slot + z_rail_x_off, outer_length - slot - rail_y_off, bed_draw_height - bed_z_dist - slot])
        scale([1, -1, 1])
        z_carriage();
    // back right
    translate([outer_width - slot - z_rail_x_off, outer_length - slot - rail_y_off, bed_draw_height - bed_z_dist - slot])
        scale([-1, -1, 1])
        z_carriage();
    
    // yellow z-motor on top
    translate([(outer_width - nema17_size) / 2, outer_length - slot - nema17_size - nema17_mount_wall, outer_height + nema17_mount_wall])
    rotate([180, 0, 90]) {
        color("yellow")
        translate([0, 0, -65])
            nema17(65);
        
        color("green")
        nema17_mount(slot);
        
        // blue motor pulley
        color("orange")
        translate([nema17_size / 2, nema17_size / 2, 8.2])
            gt2_pulley();
    }
}

// #######################################################
// ###################### Extruders ######################
// #######################################################

module extruders() {
    w = nema17_size + 25;
    translate([0, -bracket_height, outer_height - slot])
    rotate([0, 0, 90]) {
        translate([0, -(outer_width + w) / 4, 0])
            extruder(slot, "1");
        translate([0, -(outer_width + w) / 2, 0])
            extruder(slot, "2");
        translate([0, -(outer_width + w) * 3 / 4, 0])
            extruder(slot, "3");
    }
}

// ########################################################
// ####################### Assembly #######################
// ########################################################

module assembly() {
    if (show_outer_frame) {
        frame();
    }

    if (show_xy_motion) {
        motion_xy();
    }
    
    if (show_extruders) {
        extruders();
    }

    if (show_z_motion) {
        motion_z();
    }
    
    if (show_heatbed_frame) {
        heatbed();
    }
}

assembly();