refresh

README.md

@@ -6,7 +6,7 @@
 - ***Mount Anything:*** Perfect for organizing SBCs, mini PCs, small switches, power hubs, etc.
 - ***Fully customizable:*** Fully written in OpenSCAD. Everything, from the dimensions of the rack, to the roundness of the corners, can be modified with a simple code change.
 - ***Printable from home:*** Designed to be printed with conventional FDM printers. Requires minimal supports when printing, and final assembly needs only a few easy-to-source parts. 
-- ***No cage nuts!*** Sliding hex nut design for the front rails allows one to easily mount items without dealing with cage nuts.
+- ***No cage nuts!*** Sliding hex nut design for the front rails allows one to easily mount items, without dealing with cage nuts.
 - ***Stackable:*** Individual racks can be easily stacked and fastened together. Mix and match different color and design combinations!
 
 ## Assembly
@@ -51,9 +51,9 @@ Please see [the assembly README here](./assembly-guide)
 | [Feet](./rack/print/feet_P.scad) (optional)                  | 2        |
 
 
-
 #### Notes: 
-
+- Before printing the actual parts. It's recommended to print this evaluation part: [eval_P](./rack/print/eval_P.scad) to test tolerances. If you find the fits too tight/loose, you can adjust them [here](./config/slack.scad).
+- Please also adjust [this file](./config/slicer.scad) to match your slicer settings.
 - Omitted actual plastic for printing. Any conventional 3d printing plastic should do (PLA, PETG, ABS),
 but beware of PLA's thermal limits. Higher infill is recommended for all parts.
 - For joining two racks, you will need to print 4 [stackConnectorDuals](./rack/print/stackConnectorDual_P.scad), as well as 8 M3 hex nuts, and 8 M3x12 FHCS.
@@ -73,18 +73,10 @@ Generate all project files for the `micro` profile:
 
 `python3 rbuild.py -b all -c micro`
 
-This will build all the required STLs for a micro rack in the `stl/custom/` directory. 
+This will build all the parts defined in [rack/print](./rack/print), and put the STLs in [stl/micro](./stl/micro). 
 
 For generating a specific part: 
 
 `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/slicer.scad) to match your
-slicer settings.
+`rbuild.py` also support an optional `--nightly` flag, which means the build script will use the `openscad-nightly` command, instead of `openscad`.

rack-mount/print/boxHolderHelper_P.scad

@@ -1,8 +0,0 @@
-include <../../rack/sharedVariables.scad>
-use <../frontBoxHolder.scad>
-use <../sideRail.scad>
-
-
-module boxHolderHelper() {
-
-}

rack-mount/print/frontBoxHolder_P.scad

@@ -5,12 +5,12 @@ frontBoxHolder(
   u=2,
   plateThickness=3,
   cutoutOffsetX=(rackMountScrewWidth-147)/2,
-  cutoutOffsetY=2,
+  cutoutOffsetY=4.25,
   cutoutX=147,
-  cutoutY=26,
+  cutoutY=21.5,
   support=true,
-  supportedZ = 27.5,
+  supportedZ = 26.5,
   supportWidth=120,
   supportDepth=5,
-  supportRailBaseThickness=1.25
+  supportRailBaseThickness=1.75
 );

rack-mount/print/sideSupportRail_P1.scad

@@ -1,3 +1,3 @@
 use <../sideRail.scad>
 
-sideSupportRailBase(u=2, double=true, top=true, baseThickness=1.5, sideThickness=4, backThickness=2, supportedZ=27.5, supportedY=101.5, supportedX=159);
+sideSupportRailBase(u=2, double=true, top=true, baseThickness=1.5, sideThickness=4, backThickness=2, supportedZ=27.2, supportedY=101.5, supportedX=159);

rack-mount/print/sideSupportRail_P2.scad

@@ -1,4 +1,4 @@
 use <../sideRail.scad>
 
 mirror(v=[1,0,0])
-sideSupportRailBase(u=2, double=true, top=true, baseThickness=1.5, sideThickness=4, backThickness=2, supportedZ=27.5, supportedY=101.5, supportedX=159);
+sideSupportRailBase(u=2, double=true, top=true, baseThickness=1.5, sideThickness=4, backThickness=2, supportedZ=27.2, supportedY=101.5, supportedX=159);

rack-mount/sideRail.scad

@@ -3,7 +3,7 @@ include <../config/common.scad>
 include <../rack/sharedVariables.scad>
 include <./common.scad>
 
-sideSupportRailBase(u=2, double=true, top=true, baseThickness=1.5, sideThickness=4, backThickness=2, supportedZ=27.5, supportedY=101.5, supportedX=159);
+sideSupportRailBase(u=2, double=true, top=true, baseThickness=1.5, sideThickness=4, backThickness=2, supportedZ=27.2, supportedY=101.5, supportedX=159);
 
 // distance between front and back main rail screw mounts
 sideRailScrewMountDist = yBarDepth - 2*(frontScrewSpacing + railFrontThickness + railSlotToXZ);
@@ -13,18 +13,22 @@ module sideSupportRailBase(u=2, double=true, top=true, baseThickness=2, sideThic
   mountBlockHeight = 10;
   mountBlockDepth = 10;
   screwMountGlobalDz = screwDiff / 2.0; // vertical distance between local origin and main rail screw mount
-  railLength = max(sideRailScrewMountDist + frontScrewSpacing + mountBlockDepth, supportedY+backThickness);
+  sideRailScrewToMainRailFrontDx = frontScrewSpacing+railFrontThickness;
+  railLength = max(sideRailScrewMountDist + sideRailScrewToMainRailFrontDx + mountBlockDepth/2, supportedY+backThickness);
   railBaseThickness = baseThickness;
   railSideThickness = sideThickness;
   railBaseWidth = 15;
-  railSideHeight = supportedZ + railBaseThickness*2;
-  frontMountPad = frontScrewSpacing;
+  railSideHeight = supportedZ + railBaseThickness*2 + overhangSlack;
+
+  frontMountPad = (sideRailScrewToMainRailFrontDx-mountBlockDepth/2)-xySlack;
 
   applyMainRailMounts()
   sideSupportRailBase();
 
-  module applyMainRailMounts() {
+  echo(frontScrewSpacing);
+  echo(sideRailScrewToMainRailFrontDx);
 
+  module applyMainRailMounts() {
     mountBlockExtension = (railSupportsDx - supportedX)/2 - railSideThickness;
     assert(mountBlockExtension >= 10);
 

rbuild.py

@@ -7,24 +7,27 @@ import os
 PATH_TO_OPENSCAD = '/usr/bin/openscad'
 PATH_TO_OPENSCAD_NIGHTLY = '/snap/bin/openscad-nightly'
 
+
 # For actual dimensions, please see profiles.scad.
 class BuildSizeConfig:
     NANO = 'nano'
     MINI = 'mini'
     MICRO = 'micro'
 
-RACK_BUILD_DIR = './rack/print'
-RACK_MOUNT_BUILD_DIR = './rack-mount/print'
 
-BUILD_PARENT_DIR = './stl'
+FILE_DIR = os.path.dirname(os.path.abspath(__file__))
+
+RACK_BUILD_DIR = os.path.join(FILE_DIR, 'rack/print')
+RACK_MOUNT_BUILD_DIR = os.path.join(FILE_DIR, 'rack-mount/print')
+BUILD_PARENT_DIR = os.path.join(FILE_DIR, 'stl')
 
 RACK_BUILD_TARGET_SUB_DIR = 'rack'
 RACK_MOUNT_BUILD_TARGET_SUB_DIR = 'rack-mount'
 
-ASSEMBLY_GIF_DIR = './rack/assembly'
-ASSEMBLY_GIF_BUILD_DIR = './assembly-guide/gifs'
-ASSEMBLY_GIF_TEMP_DIR = ASSEMBLY_GIF_BUILD_DIR + '/tmp'
-BUILD_GIF_FROM_PNG_SCRIPT = './misc/animate.sh'
+ASSEMBLY_GIF_DIR = os.path.join(FILE_DIR, 'rack/assembly')
+ASSEMBLY_GIF_BUILD_DIR = os.path.join(FILE_DIR, 'assembly-guide/gifs')
+ASSEMBLY_GIF_TEMP_DIR = os.path.join(ASSEMBLY_GIF_BUILD_DIR, 'tmp')
+BUILD_GIF_FROM_PNG_SCRIPT = os.path.join(FILE_DIR, 'misc/animate.sh')
 
 ASSEMBLY_STEPS = [
     ('slideHexNutsIntoYBar.scad', 24),
@@ -44,10 +47,11 @@ ASSEMBLY_STEPS = [
     ('attachXYPlates.scad', 16)
 ]
 
-def main():
 
+def main():
     if not assertOpenscadExists():
-        print("Could not find OpenSCAD binary. Please make sure it's configured in rbuild.py. Currently only Darwin and Linux have been tested to work.")
+        print(
+            "Could not find OpenSCAD binary. Please make sure it's configured in rbuild.py. Currently only Darwin and Linux have been tested to work.")
 
     parser = argparse.ArgumentParser(
         prog='rbuild',
@@ -101,7 +105,6 @@ def main():
 
 
 def run_build(args):
-
     build_var = args.b
     config_var = args.c
     target_var = args.t
@@ -111,11 +114,11 @@ def run_build(args):
 
     if (build_var is not None) == (build_gifs is True):
         print("Please either provide the build (-b) variable, or the build-gifs option (--build-assembly-gifs)")
-        quit()
+        return
 
     if build_gifs:
         build_assembly_gifs(config_var, dz, nightly)
-        quit()
+        return
 
     if target_var != "":
         final_target_directory_name = target_var
@@ -123,7 +126,8 @@ def run_build(args):
         final_target_directory_name = config_var
 
     rackBuildDirFull = os.path.join(BUILD_PARENT_DIR, final_target_directory_name, RACK_BUILD_TARGET_SUB_DIR)
-    rackMountBuildDirFull = os.path.join(BUILD_PARENT_DIR, final_target_directory_name, RACK_MOUNT_BUILD_TARGET_SUB_DIR)
+    rackMountBuildDirFull = os.path.join(BUILD_PARENT_DIR, final_target_directory_name,
+                                         RACK_MOUNT_BUILD_TARGET_SUB_DIR)
 
     if not os.path.exists(rackBuildDirFull):
         os.makedirs(rackBuildDirFull)
@@ -136,7 +140,8 @@ def run_build(args):
             build_single(RACK_BUILD_DIR, rackBuildDirFull, dir_file, config_var, dz, nightly)
 
         for dir_file in os.listdir(RACK_MOUNT_BUILD_DIR):
-            build_single(RACK_MOUNT_BUILD_DIR, rackMountBuildDirFull, dir_file, config_var, dz, nightly)
+            build_single(RACK_MOUNT_BUILD_DIR, rackMountBuildDirFull, dir_file, config_var, dz,
+                         nightly)
         return
 
     filename_rack = find_rack(build_var)
@@ -152,11 +157,13 @@ 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)
     run_openscad(openscad_args, nightly)
 
+
 def build_assembly_gifs(config, dz, nightly):
     print('Building assembly-gifs. Source Dir:', ASSEMBLY_GIF_DIR, '| Target:', ASSEMBLY_GIF_BUILD_DIR)
 
@@ -168,11 +175,10 @@ def build_assembly_gifs(config, dz, nightly):
         run_openscad(openscad_args, nightly)
         build_gif_from_png(fileName)
 
+
 def build_gif_from_png(fileName):
-    script_dir = os.path.dirname(os.path.abspath(__file__))
-    script_path = os.path.join(script_dir, BUILD_GIF_FROM_PNG_SCRIPT)
     try:
-        subprocess.run(["bash", script_path, fileName], check=True)
+        subprocess.run(["bash", BUILD_GIF_FROM_PNG_SCRIPT, fileName], check=True)
     except subprocess.CalledProcessError as e:
         print(f"Error calling shell script: {e}")
 
@@ -209,7 +215,6 @@ def construct_openscad_animation_args(build_dir, target_dir, filename, config, d
     return openscad_args
 
 
-
 def find_rack(filename):
     return find_scad_file(RACK_BUILD_DIR, filename)
 
@@ -236,7 +241,6 @@ def find_scad_file(directory, filename):
 
 
 def run_openscad(options, nightly):
-
     if nightly:
         command = [PATH_TO_OPENSCAD_NIGHTLY, '--enable', 'all']
     else:
@@ -250,8 +254,11 @@ def run_openscad(options, nightly):
         print('OpenSCAD command not found! '
               'Please make sure that you have the OpenSCAD binary configured in rbuild.py.'
               '(Currently needs Linux/Mac for this)')
+
+
 def assertOpenscadExists():
     return os.path.exists(PATH_TO_OPENSCAD)
 
+
 if __name__ == '__main__':
     main()