update sidewalls

README.md

@@ -56,19 +56,19 @@ Requirements:
 ### Examples:
 Generate all project files for the `micro` profile:
 
-`python3 rbuild.py -b all --nightly -c micro`
+`python3 rbuild.py -b all -c micro`
 
-This will build all the required STLs for a micro rack in the `stl/custom/` directory. The `--nightly` is optional and
+This will build all the required STLs for a micro rack in the `stl/custom/` directory. 
-means the build script will use the `openscad-nightly` command, instead of `openscad`. This usually results in much
-faster build times and is generally recommended.
 
 For generating a specific part: 
 
-`python3 rbuild.py -b yBar --nightly -c micro -t custom`
+`python3 rbuild.py -b yBar -c micro -t custom`
 
 Generated stls are put into the `stl/` directories. The actual variable values for different profiles can be found in 
 [rack/profiles.scad](config/rackFrame.scad).
 
+`rbuild.py` also support an optional `--nightly` flag, which means the build script will use the `openscad-nightly` command, instead of `openscad`.
+
 We recommend you start by printing the `eval_P.stl` file first, just to determine if the default slack/layer height
 configurations work for you. If parts are too tight/loose please take a look at
 [config/slack.scad](config/slack.scad). Please also adjust [config/printing.scad](config/printing.scad) to match your

config/slack.scad

@@ -13,15 +13,15 @@
     - These values depend on print orientation and it's assumed parts are printed in their recommended orientations.
 */
 
-xySlack = 0.3;
+xySlack = 0.4;
 
 radiusXYSlack = xySlack/2;
 
-zSlack = 0.2;
+zSlack = 0.0;
 
-overhangSlack = 0.4;
+overhangSlack = 0.7;
 
-supportedOverhangSlack = 0.4;
+supportedOverhangSlack = 0.7;
 
 // special slack cases, change if neccessary
 xBarYBarDovetailSlack = xySlack;

rack-mount/bottomScrewTray.scad

@@ -5,7 +5,7 @@ use <./rackEars.scad>
 
 // Config variables
 //trayAlignment = "middle"; // middle, right, left
-trayWidth = 150;
+trayWidth = 110;
 trayDepth = 100;
 trayThickness = 3;
 
@@ -17,26 +17,47 @@ bottomScrewTray(u=5);
 
 module bottomScrewTray(u) {
 
-  screwDx = rackMountScrewWidth;
+
-  echo(screwDx);
+  frontLipHeight = 5;
+  backLipHeight = 5; // also applies to sides
+  lipThickness = 3;
+
+  rackEarSideThickness = 3;
+  rackEarFrontThickness = 3;
+
+  screwDx = rackMountScrewWidth; // x dist between the mount holes
   screwDz = uDiff * u;
 
   plateLength = screwDx + 2*rackMountScrewXDist;
   plateHeight = screwDz + 2*rackMountScrewZDist;
 
-  leftScrewDistToTray = 10+4+3;
+  minScrewToTraySpacing = 8;
-  assert(leftScrewDistToTray >= 5);
+
+  // TODO: toggle this based on left/right/middle alignment
+  leftScrewDistToTray = minScrewToTraySpacing + 2 +5;
 
   leftScrewGlobalX = -leftScrewDistToTray;
   rightScrewGlobalX = screwDx + leftScrewGlobalX;
 
   cube(size=[trayWidth, trayDepth, trayThickness]);
 
-  translate(v=[rackMountScrewXDist+leftScrewGlobalX+3,0,rackMountScrewZDist])
+  translate(v=[0,0,trayThickness])
-  rackEarModule(frontThickness=3,sideThickness=3,frontWidth=leftScrewDistToTray, sideDepth=trayDepth-3, u=5);
+  cube(size=[trayWidth, lipThickness, frontLipHeight]);
+
+  translate(v=[0,trayDepth-lipThickness,trayThickness])
+  cube(size=[trayWidth, lipThickness, backLipHeight]);
+
+  translate(v=[0,0,trayThickness])
+  cube(size=[lipThickness, trayDepth, backLipHeight]);
+
+  translate(v=[trayWidth-lipThickness,0,trayThickness])
+  cube(size=[lipThickness, trayDepth, backLipHeight]);
+
+  translate(v=[leftScrewGlobalX,0,rackMountScrewZDist])
+  rackEarModule(frontThickness=rackEarFrontThickness,sideThickness=rackEarSideThickness,frontWidth=leftScrewDistToTray+rackMountScrewXDist+rackEarSideThickness, sideDepth=trayDepth-lipThickness, u=u);
 
   translate(v=[rightScrewGlobalX,0,rackMountScrewZDist])
   mirror(v=[1,0,0])
-  rackEarModule(frontThickness=3,sideThickness=3,frontWidth=30, sideDepth=trayDepth-3, u=5);
+  rackEarModule(frontThickness=rackEarFrontThickness,sideThickness=rackEarSideThickness,frontWidth=rightScrewGlobalX-trayWidth+rackMountScrewXDist+rackEarSideThickness, sideDepth=trayDepth-lipThickness, u=u);
 
 }

rack/side/hingeModule.scad

@@ -4,7 +4,7 @@ include <../sharedVariables.scad>
 include <./sideWallVariables.scad>
 
 translate(v=[10,20,-2 - sideWallZHingeTotalClearance])
-hingeModule();
+*hingeModule();
 
 module hingeModule() {
 

rack/side/magnetModule.scad

@@ -4,7 +4,7 @@ include <../sharedVariables.scad>
 include <./sideWallVariables.scad>
 
 translate(v=[10,-5,-(2+sideWallZHingeTotalClearance)])
-magnetModule();
+*magnetModule();
 
 magnetModuleMagnetMountDy = magnetMountToYBarFront - sideWallSlotToXZ;
 magnetModuleMagnetMountDz = magnetMountToYBarTop + sideWallConnLugDepression;

rack/side/sideWallLeft.scad

@@ -5,13 +5,13 @@ sideWallLeft();
 module sideWallLeft() {
 
   applySideWallVerticalRibs()
-  //applyEpicVentilation()
+  applyEpicVentilation()
   sideWallBase();
 
   module applyEpicVentilation() {
     apply_n() {
       for (i = [1:8]) {
-        translate(v = [0, 41, i * 18 + 10])
+        translate(v = [0, 41, i * 12 + 10])
         vent();
       }
       children(0);
@@ -20,17 +20,18 @@ module sideWallLeft() {
     module vent() {
       minkowski() {
         rotate(a=[0,90,0])
-        cylinder(r=1,h=1);
+        cylinder(r=2,h=1);
 
-        cube(size = [10, 80, 5]);
+        cube(size = [10, 100, 1]);
       }
     }
   }
 
   module applySideWallVerticalRibs() {
+    echo("sideWallZ", sideWallZ);
     apply_p() {
-      translate(v = [0, 20, 0])
+      translate(v = [0, 30, 0])
-      sideWallVerticalRibs(numRibs = 9, ribZ = sideWallZ, ribYDiff = 20, ribExtrusion = 1.5);
+      sideWallVerticalRibs(numRibs = 2, ribZ = sideWallZ, ribYDiff = 120, ribExtrusion = 1.5);
 
       children(0);
     }

rack/side/sideWallRight.scad

@@ -4,17 +4,17 @@ sideWallRight();
 
 module sideWallRight() {
 
-  //applyEpicVentilation()
+  applyEpicVentilation()
   mirror(v=[1,0,0])
   applySideWallVerticalRibs()
-  //render()
   sideWallBase();
 
   module applyEpicVentilation() {
 
     apply_n() {
+      translate(v=[-10,0,0])
       for (i = [1:8]) {
-        translate(v = [0, 41, i * 18 + 10])
+        translate(v = [0, 41, i * 12 + 10])
         vent();
       }
       children(0);
@@ -22,8 +22,10 @@ module sideWallRight() {
 
     module vent() {
       minkowski() {
-        sphere(r=1);
+        rotate(a=[0,90,0])
-        cube(size = [10, 40, 3]);
+        cylinder(r=2,h=1);
+
+        cube(size = [10, 100, 1]);
       }
     }
 
@@ -31,8 +33,8 @@ module sideWallRight() {
 
   module applySideWallVerticalRibs() {
     apply_p() {
-      translate(v = [0, 20, 0])
+      translate(v = [0, 30, 0])
-      sideWallVerticalRibs(numRibs = 9, ribZ = sideWallZ, ribYDiff = 20, ribExtrusion = 1.5);
+      sideWallVerticalRibs(numRibs = 2, ribZ = sideWallZ, ribYDiff = 120, ribExtrusion = 1.5);
 
       children(0);
     }

rbuild.py

@@ -115,7 +115,6 @@ def run_build(args):
     if filename_rack_mount:
         build_single(RACK_MOUNT_BUILD_DIR, rackMountBuildDirFull, filename_rack, config_var, dz, nightly)
 
-
 def build_single(build_dir, target_dir, filename, config, dz, nightly):
     print('Building:', filename, 'from', build_dir, 'to', target_dir)
     openscad_args = construct_openscad_args(build_dir, target_dir, filename, config, dz)
@@ -171,7 +170,7 @@ def run_openscad(options, nightly):
     else:
         command = ['openscad']
 
-    command += ['-q', '--export-format', 'binstl'] + options
+    command += ['--export-format', 'binstl'] + options
     try:
         subprocess.check_output(command, universal_newlines=True, stderr=subprocess.DEVNULL)