add instructions and renders

README.md

@@ -1,34 +1,39 @@
 # rackstack
 
-![mini](media/renders/mini-cropped.png)
+![display](media/renders/rackDisplay.png)
 
-A parametric 3d-printable (mini) rack system.
-
-- ***Not just STLs:*** 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.
+### A parametric 3d-printable mini rack system
+- ***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!*** 
-- ***Stackable:*** Individual racks can be easily stacked together. Mix and match different color and design combinations!
+- ***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!
 
 ### Renders
 See the [renders for difference parametric profiles here](media/renders)
 
-## Features
-
-Sliding nut design for the front rails allows one to easily mount items without dealing with cage nuts.
-
-![slidingNuts](media/features/slide.gif) 
-
-Individual racks can be stacked and fastened together. 
-![stackable](media/features/stackConnector.gif) 
-
-There's also cool magnetic side doors.
-![swivelSideDoor](media/features/swivel.gif)
-
-
 ## Assembly
 
+Pre-generated STLs for roughly 200mm^3, and 100mm^3 rack frames can be found in [stl/rack](stl/rack).
+These STLs are generated from the files in [rack/print](rack/print), and [rack-mount/print](rack-mount/print) - further information about printing these parts 
+(supports, orientation) can be found in their respective `.scad` files.
+
+### Assembly Instructions
+
 ### BOM
 
+TODO
+
+- A bunch of m3 screws for constructing the actual rack.
+- A bunch of m4 screws for the main rails
+- Some heatset inserts
+- A bunch of m3 hex nuts
+- m3 allen key (preferably with a rounded end)
+- m4 allen key
+- 2 dowel pins
+- 8 magnets
+
+
 ## Configuring + Generating STLs
 
-
+TODO

rack-mount/side-rail/dualMount.scad

@@ -2,26 +2,29 @@ include <../../helper/common.scad>
 include <../../helper/math.scad>
 include <../../helper/screws.scad>
 include <../../rack/config.scad>
+include <../../rack/sharedVariables.scad>
 
 *sideSupportRailBase("lBracket");
+// TODO: make this parametric
+
+// distance between front and back main rail screw mounts
+sideRailScrewMountDist = yBarDepth - 2*(frontScrewSpacing + railFrontThickness + railSlotToXZ); // TODO use transformation matrices
 
 module sideSupportRailBase(type) {
 
-  railLength = 100;
-  railBaseThickness = 2;
-  railBaseWidth = 18;
-  railSideThickness = 2;
-  railSideHeight = 12;
-  sideDy = -2;
-
-  frontMountPad = 10; // depends on y of box to be mounted TODO calculate this
-  sideMountPad = 10; // depends on x of box TODO calculate this
-  // distance between front and back main rail screw mounts
-  screwMountDist = 62; // TODO calculate this instead of hardcode
   // vertical distance between local origin and main rail screw mount
   screwMountGlobalDz = screwDiff / 2.0;
 
+  railLength = sideRailScrewMountDist + 30; // TODO calculate this
+  railBaseThickness = 2;
+  railBaseWidth = 18;
+  railSideThickness = 2;
+  railSideHeight = 15;
+  sideDy = -2;
+  frontMountPad = 10; // depends on y of box to be mounted TODO calculate this
+  sideMountPad = 10; // depends on x of box TODO calculate this
 
+  translate(v=[sideMountPad,-(frontMountPad + 5),-5])
   applyMainRailMounts()
   sideSupportRailBaseHolder();
 
@@ -41,7 +44,7 @@ module sideSupportRailBase(type) {
       union() {
         dualMount();
 
-        translate(v=[0,screwMountDist,0])
+        translate(v=[0,sideRailScrewMountDist,0])
         dualMount();
       }
 

rack/assemblyGuide.scad

@@ -10,10 +10,16 @@ include <./side/sideWallLeft.scad>
 include <./stackEnds.scad>
 include <./xyPlate.scad>
 
+include <../rack-mount/side-rail/dualMount.scad>
+
 assemblyInstructions();
 
 module assemblyInstructions () {
 
+  screwMask = false;
+  plasticMask = true;
+  sideSupportRailMask = true;
+
   // Instruction List (in order)
   // render()
   // addHeatSetInsertsYBar(at=$t);
@@ -37,7 +43,6 @@ module assemblyInstructions () {
    finalSingle();
   // finalDouble();
 
-
   // Features:
   // render()
   // slideInNuts(at=$t);
@@ -48,7 +53,9 @@ module assemblyInstructions () {
   module addHeatSetInsertsYBar(at=0) {
     t = lerp(a=10,b=0.35,t=at); // non zero b for exposing the heatset gears for diagramming
 
+    if (!plasticMask) {
       yBar();
+    }
 
     heatSetHeight = heatSetInsertSlotHeightSlacked(rackFrameScrewType) * 0.95;
 
@@ -76,17 +83,21 @@ module assemblyInstructions () {
       heatSetInsert(rackFrameScrewType);
     }
 
-    heatSetInsertsOneCorner(t=t);
+    if (!screwMask) {
+      heatSetInsertsOneCorner(t = t);
 
       multmatrix(yBarMirrorOtherCornerTrans)
-    heatSetInsertsOneCorner(t=t);
+      heatSetInsertsOneCorner(t = t);
+    }
 
   }
 
   module addMagnetsToMagnetModules(at=0) {
     t = lerp(a=8,b=0,t=at);
 
+    if (!plasticMask) {
       magnetModule();
+    }
 
     function insertMagnetTrans(t=0) =
       translate(v=[sideWallConnW-(magnetFaceToSideWallConnOuterYEdge+magnetHSlacked) + t,
@@ -101,7 +112,9 @@ module assemblyInstructions () {
   module addMagnetsToSideWall(at=0) {
     t = lerp(a=8,b=0,t=at);
 
+    if (!plasticMask) {
       sideWallLeft();
+    }
 
     function insertMagnetTrans(t=0) =
       translate(v=[sideWallThickness+t, magnetMountToYBarFront, magnetMountToYBarTop-sideWallZHingeTotalClearance]) *
@@ -125,12 +138,14 @@ module assemblyInstructions () {
     multmatrix(translate(v = [0, 0, t])*xBarSpaceToYBarSpace*xBarMirrorOtherCornerTrans*yBarSpaceToXBarSpace)
     addHeatSetInsertsYBar(at=1);
 
+    if (!plasticMask) {
       multmatrix(xBarSpaceToYBarSpace)
       xBar();
 
       multmatrix(yBarMirrorOtherCornerTrans*xBarSpaceToYBarSpace)
       xBar();
     }
+  }
 
   module screwXBarAndYBar(at=0) {
     screwExtension = lerp(a=15, b=0, t=at);
@@ -147,7 +162,8 @@ module assemblyInstructions () {
 
     multmatrix(xBarSpaceToYBarSpace)
     union() {
-      xBar();
+
+      if (!plasticMask) { xBar(); }
 
       multmatrix(xBarYBarScrewTrans(screwExtension))
       caseScrewB();
@@ -158,7 +174,7 @@ module assemblyInstructions () {
 
     multmatrix(yBarMirrorOtherCornerTrans*xBarSpaceToYBarSpace)
     union() {
-      xBar();
+      if (!plasticMask) { xBar(); }
 
       multmatrix(xBarYBarScrewTrans(screwExtension))
       caseScrewB();
@@ -197,7 +213,10 @@ module assemblyInstructions () {
 
     multmatrix(yBarMirrorOtherCornerTrans * sideModuleTrans(elevation))
     union() {
+
+      if (!plasticMask) {
         hingeModule();
+      }
 
       translate(v=[yBarScrewHoleToOuterYEdge,yBarScrewHoleToFrontXEdge,sideWallConnLugDepression + 2*elevation])
       caseScrewA();
@@ -205,7 +224,9 @@ module assemblyInstructions () {
 
     multmatrix(xBarSpaceToYBarSpace * xBarMirrorOtherCornerTrans * yBarSpaceToXBarSpace * yBarMirrorOtherCornerTrans * sideModuleTrans(elevation))
     union() {
+      if (!plasticMask) {
         hingeModule();
+      }
 
       translate(v=[yBarScrewHoleToOuterYEdge,yBarScrewHoleToFrontXEdge,sideWallConnLugDepression + 2*elevation])
       caseScrewA();
@@ -221,7 +242,10 @@ module assemblyInstructions () {
     function mainRailTrans(elevation) = translate(v=[0,0,elevation]) * yBarMainRailConnectorTrans;
 
     module railAndScrew(elevation) {
+
+      if (!plasticMask) {
         mainRail();
+      }
 
       translate(v=[railSideMountThickness + 5, railFrontThickness + 4,railFootThickness + 2*elevation])
       caseScrewA();
@@ -322,8 +346,10 @@ module assemblyInstructions () {
         caseScrewA();
       }
 
-      translate(v=[0,0,-t])
+      if (!plasticMask) {
+        translate(v = [0, 0, -t])
         xyPlate();
+      }
 
       screw(t=2*t);
 
@@ -343,10 +369,12 @@ module assemblyInstructions () {
     t = lerp(a=8, b=0, t=at);
 
     module slideNut() {
+      if (!screwMask) {
         rotate(a = [0, 0, 90])
         rotate(a = [90, 0, 0])
         hexNut(rackFrameScrewType);
       }
+    }
 
     translate(v=[0,t,connectorBottomToScrew + 0.5]) // where does this come from again? slack?
     slideNut();
@@ -354,8 +382,10 @@ module assemblyInstructions () {
     translate(v=[stackConnectorDx,t,connectorBottomToScrew + 0.5]) // where does this come from again? slack?
     slideNut();
 
+    if (!plasticMask) {
       stackConnectorFeet();
     }
+  }
 
   module insertFeet(at=0,r=0) {
 
@@ -397,16 +427,47 @@ module assemblyInstructions () {
 
   module finalSingle(r=0) {
     screwFeet(at=1,r=r);
+
+    for (i = [1, 5, 9, 13, 17]) {
+      translate(v = [2, frontScrewSpacing+railFrontThickness+railSlotToXZ, i*10])
+      multmatrix(yBarMainRailConnectorTrans)
+      union() {
+        if (!sideSupportRailMask) {
+          sideSupportRailBase("lBracket");
         }
 
+        rotate(a = [0, -90, 0])
+        caseScrewA();
+
+        translate(v = [0, sideRailScrewMountDist, 0])
+        rotate(a = [0, -90, 0])
+        caseScrewA();
+      }
+    }
+
+    multmatrix(xBarSpaceToYBarSpace*xBarMirrorOtherCornerTrans*yBarSpaceToXBarSpace)
+    for (i = [1, 5, 9, 13, 17]) {
+      translate(v = [2, frontScrewSpacing+railFrontThickness+railSlotToXZ, i*10])
+      multmatrix(yBarMainRailConnectorTrans)
+      union() {
+        if (!sideSupportRailMask) {
+          sideSupportRailBase("lBracket");
+        }
+        rotate(a=[0,-90,0])
+        caseScrewA();
+
+        translate(v=[0,sideRailScrewMountDist,0])
+        rotate(a=[0,-90,0])
+        caseScrewA();
+      }
+    }
+  }
+
+
   module finalDouble(r=0) {
-    multmatrix(secondStackTrans)
-    attachXYPlates(at=1,r=r);
-
-    screwFeet(at=1,r=r);
+    stackable(at=1,r=r);
   }
 
-
   module slideInNuts(at=0) {
 
     t = lerp(a=15,b=0,t=at);
@@ -445,7 +506,7 @@ module assemblyInstructions () {
     stackConnectorDual();
   }
 
-  module stackable(at=0) {
+  module stackable(at=0,r=0) {
 
     t1 = lerp(a=0, b=1,  t=min(3*at, 1));
     t2 = lerp(a=30, b=0, t=min(max(3*at-1,0),1));
@@ -465,8 +526,10 @@ module assemblyInstructions () {
       caseScrewB();
     }
 
-    translate(v=[0,0,t2/2])
+    if (!plasticMask) {
+      translate(v = [0, 0, t2/2])
       stackConnectors();
+    }
 
     if (at >= 2/3) {
       multmatrix(secondStackTrans)
@@ -478,9 +541,9 @@ module assemblyInstructions () {
 
     translate(v=[0,0,t2])
     multmatrix(secondStackTrans)
-    attachXYPlates(at=1);
+    attachXYPlates(at=1,r=r);
 
-    screwFeet(at=1);
+    screwFeet(at=1,r=20);
 
   }
 
@@ -490,10 +553,6 @@ module assemblyInstructions () {
     finalSingle(r=r);
   }
 
-  module parametric() {
-
-  }
-
   xBarSpaceToYBarSpace =
       yBarXBarConnectorTrans *
       xBarConnectorToYBarConnectorTrans *
@@ -535,7 +594,8 @@ module assemblyInstructions () {
 
 
   module caseScrewA() {
-    color([1,1,1]) {
+    if (!screwMask) {
+      color([1, 1, 1]) {
         difference() {
           scale(v = [0.9, 0.9, 0.9])
           counterSunkHead_N(rackFrameScrewType, screwExtension = 6, headExtension = 0.5);
@@ -544,9 +604,11 @@ module assemblyInstructions () {
         }
       }
     }
+  }
 
   module caseScrewB() {
-    color([1,1,1]) {
+    if (!screwMask) {
+      color([1, 1, 1]) {
         difference() {
           scale(v = [0.9, 0.9, 0.9])
           counterSunkHead_N(rackFrameScrewType, screwExtension = 10, headExtension = 0.5);
@@ -555,16 +617,21 @@ module assemblyInstructions () {
         }
       }
     }
+  }
 
   module hingeDowel() {
-    color([0,1,1])
-    cylinder(h=dowelPinH, r=dowelPinR);
+    if (!screwMask) {
+      color([0, 1, 1])
+      cylinder(h = dowelPinH, r = dowelPinR);
+    }
   }
 
 
   module magnet() {
-    color([1,1,1])
-    cylinder(r=magnetR, h=magnetH);
+    if (!screwMask) {
+      color([1, 1, 1])
+      cylinder(r = magnetR, h = magnetH);
+    }
   }
 
   module arrow(length) {

rack/config.scad

@@ -8,7 +8,7 @@
 */
 include <./profiles.scad>
 
-profileName = "micro";
+profileName = "default";
 profile = getProfile(profileName);
 
 // echo("Profile:", profile);

rack/side/sideWallLeft.scad

@@ -5,8 +5,8 @@ include <./sideWallBase.scad>
 module sideWallLeft() {
 
   //applyEpicVentilation()
-  applySideWallVerticalRibs()
-  render()
+  //applySideWallVerticalRibs()
+  //render()
   sideWallBase();
 
   module applyEpicVentilation() {

rack/side/sideWallRight.scad

@@ -6,8 +6,8 @@ module sideWallRight() {
 
   //applyEpicVentilation()
   mirror(v=[1,0,0])
-  applySideWallVerticalRibs()
-  render()
+  //applySideWallVerticalRibs()
+  //render()
   sideWallBase();
 
   module applyEpicVentilation() {