update stl build dir structure

README.md

@@ -14,44 +14,53 @@ See the [renders for difference parametric profiles here](media/renders)
 
 ## Assembly
 
-Pre-generated STLs for roughly 200mm^3, and 100mm^3 rack frames can be found in [stl/rack](stl/rack).
+Pre-generated STLs for roughly 200mm^3 (mini), 170mm^3 (micro), and 100mm^3 (nano) rack frames can be found in [stl](stl).
 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.
+(supports, orientation) can be found in these files.
 
 ### Assembly Instructions
-Please see [the assembly README here](./assembly)
+Please see [the assembly README here](./assembly-guide)
 
 ### Required Tools:
-- 3d FDM Printer - build size requirements depend on configure rack size. (TODO explain)
+- 3d FDM Printer - build size requirements depend on configured rack profile
 - M3 Allen Key
 - M4 Allen Key
 
 ### BOM - Single Rack:
 
 | Item                                                          | Name                      | Quantity | Comment                                                                                                                         |
-|----------------------------------------------------------|---------------------------|----------|---------------------------------------------------------------------------------------------------------------------------|
-| <img src="media/bom/m3_8.gif"  height="60" width="72">   | M3x8 FHCS                 | 16       | Spares are useful and inexpensive. If you plan on eventually stacking multiple racks together don't hesitate to get more. |
-| <img src="media/bom/m3_10.gif"  height="60" width="72">  | M3x10 FHCS                | 4        | ☝️                                                                                                                        |
-| <img src="media/bom/m3_12.gif"  height="60" width="72">  | M3x12 FHCS                | 16       | ☝️                                                                                                                        |
-| <img src="media/bom/m3_hex.gif"  height="60" width="72"> | M3 hex nut                | 36       | ☝️                                                                                                                        |
+|---------------------------------------------------------------|---------------------------|----------|---------------------------------------------------------------------------------------------------------------------------------|
+| <img src="media/bom/fhcs_medium.gif"  height="60" width="72"> | M3x12 FHCS                | 20       | Spares are useful and inexpensive. If you plan on eventually stacking multiple racks together don't hesitate to get a lot more. |
+| <img src="media/bom/fhcs_long.gif"  height="60" width="72">   | M3x16 FHCS                | 16       | ☝️                                                                                                                              |
+| <img src="media/bom/hex_nut.gif"  height="60" width="72">     | M3 hex nut                | 36       | ☝️                                                                                                                              |
 | <img src="media/bom/dowel.gif"  height="60" width="72">       | 3x10 steel dowel pin      | 4        | 3mm diameter, 10mm height                                                                                                       |
 | <img src="media/bom/magnet.gif"  height="60" width="72">      | 6x2 neodymium disc magnet | 8        | 6mm diameter, 2mm height                                                                                                        |
+|                                                               | super glue                |          |                                                                                                                                 |
  
 #### Notes: 
 
 - 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 8 M3 hex nuts, and 8 M3x10 FHCS (TODO confirm)
+- For joining two racks, you will need 8 M3 hex nuts, and 8 M3x12 FHCS.
 - Main front rails use M4 hex nuts and screws.
-- Side rails are mounted using M3 hex nuts and screws
+- Side rails are mounted using M3 hex nuts and screws.
 
 
 ## Configuring + Generating STLs
-
-WIP
+A python script: `rbuild.py` is provided to generate different project stls.
 
 Requirements:
   - `openscad` cli command (Only runs on Linux)
   - `python3`
 
-`python3 rbuild.py --help`
+### Examples:
+Generate all project files for the `mini` profile:
+
+`python3 rbuild.py -b all -c micro`
+
+Generate specific part: 
+
+`python3 rbuild.py -b yBar`
+
+Generated stls are put into the `stl/` directories. The actual variable values for different profiles can be found in  
+[rack/profiles.scad](rack/profiles.scad).

rack/config.scad

@@ -8,7 +8,9 @@
 */
 include <./profiles.scad>
 
+// Manually set this variable to toggle profiles
 profileName = "micro";
+
 profile = getProfile(profileName);
 
 defaultLayerHeight = 0.3;

rack/connector/connectors.scad

@@ -66,6 +66,8 @@ module connectorPositive(on, to) {
     onYBarToXBarPositive();
   } else if (on == "yBar" && to == "basePlate") {
     onYBarBasePlateConnectorPositive();
+  } else if (on == "xBar" && to == "yBar") {
+    onXBarToYBarPositive();
   } else if (on == "mainRail" && to == "yBar") {
     onMainRailYBarConnectorPositive();
   }

rack/connector/xBarYBarConnectors.scad

@@ -35,6 +35,16 @@ module onXBarToYBarNegative() {
   translate(v = [-xBarSideThickness, y, z])
   rotate(a = [0, -90, 0])
   counterSunkHead_N(rackFrameScrewType, screwExtension=inf10, headExtension=inf10);
+
+  // lugs for snap fit and hold in place
+  translate(v=[-0.1,26,13.5])
+  lug();
+}
+
+module onXBarToYBarPositive() {
+  // lugs for snap fit and hold in place
+  translate(v=[-0.1,26,2])
+  lug();
 }
 
 
@@ -46,6 +56,10 @@ module onYBarToXBarNegative() {
   rotate(a = [180, 0, 0])
   rotate(a = [0, 90, 0])
   hexNutPocket_N("m3", openSide=false, backSpace=5);
+
+  // lugs for snap fit and hold in place
+  translate(v=[-0.1,26,2])
+  lug();
 }
 
 module onYBarToXBarPositive() {
@@ -64,8 +78,22 @@ module onYBarToXBarPositive() {
       backFaceLength = 5,
       backFaceScale = 1.2
   );
+
+  // lugs for snap fit and hold in place
+  translate(v=[-0.1,26,13.5])
+  lug();
 }
 
 
 xBarConnectorToYBarConnectorTrans = mirror(v=[1,0,0]);
 yBarConnectorToXBarConnectorTrans = mirror(v=[-1,0,0]);
+
+
+module lug() {
+  hull() {
+    sphere(r=0.5);
+
+    translate(v=[0,2,0])
+    sphere(r=0.5);
+  }
+}

rack/profiles.scad

@@ -12,26 +12,29 @@
 
 _profileConfigs = [
     ["default", [
-      ["maxUnitWidth", 205],
-      ["maxUnitDepth", 205],
+      ["maxUnitWidth", 170],
+      ["maxUnitDepth", 180],
+      ["numRailScrews", 18],
       ["screwDiff", 10],
-      ["numRailScrews", 20],
       ["mainRailScrewType", "m4"],
       ["mainRailSideMountScrewType", "m4"],
       ["rackFrameScrewType", "m3"],
       ["baseRoundness", 5],
     ]],
-    ["micro", [
+    ["nano", [
       ["maxUnitWidth", 105],
       ["maxUnitDepth", 105],
-      ["numRailScrews", 10],
-      ["baseRoundness", 5]
+      ["numRailScrews", 10]
+    ]],
+    ["micro", [
+      ["maxUnitWidth", 170],
+      ["maxUnitDepth", 180],
+      ["numRailScrews", 18]
     ]],
     ["mini", [
       ["maxUnitWidth", 205],
       ["maxUnitDepth", 205],
-      ["numRailScrews", 20],
-      ["baseRoundness", 5]
+      ["numRailScrews", 20]
     ]]
   ];
 

rbuild.py

@@ -4,21 +4,22 @@ import argparse
 import subprocess
 import os
 import sys
-from stl import mesh, stl
 
 
 # For actual dimensions, please see profiles.scad.
 class BuildSizeConfig:
+    NANO = 'nano'
     MINI = 'mini'
     MICRO = 'micro'
-    DEFAULT = 'default'
 
 
 RACK_BUILD_DIR = './rack/print'
 RACK_MOUNT_BUILD_DIR = './rack-mount/print'
 
-RACK_BUILD_TARGET_DIR = './stl/rack'
-RACK_MOUNT_BUILD_TARGET_DIR = './stl/rack-mount'
+BUILD_PARENT_DIR = './stl'
+
+RACK_BUILD_TARGET_SUB_DIR = 'rack'
+RACK_MOUNT_BUILD_TARGET_SUB_DIR = 'rack-mount'
 
 
 def main():
@@ -43,8 +44,8 @@ def main():
 
     parser.add_argument(
         '-c',
-        default='default',
-        choices=[BuildSizeConfig.MINI, BuildSizeConfig.MICRO, BuildSizeConfig.DEFAULT],
+        default=BuildSizeConfig.MINI,
+        choices=[BuildSizeConfig.NANO, BuildSizeConfig.MINI, BuildSizeConfig.MICRO],
         help='Build size config profile. This will determine the size of the rack you wish to generate. '
              'For actual dimensions, please see profiles.scad.'
     )
@@ -58,13 +59,22 @@ def main():
 
 
 def run_build(build_var, config_var):
+
+    rackBuildDirFull = os.path.join(BUILD_PARENT_DIR, config_var, RACK_BUILD_TARGET_SUB_DIR)
+    rackMountBuildDirFull = os.path.join(BUILD_PARENT_DIR, config_var, RACK_MOUNT_BUILD_TARGET_SUB_DIR)
+
+    if not os.path.exists(rackBuildDirFull):
+        os.makedirs(rackBuildDirFull)
+
+    if not os.path.exists(rackMountBuildDirFull):
+        os.makedirs(rackMountBuildDirFull)
+
     if build_var == 'all':
         for dir_file in os.listdir(RACK_BUILD_DIR):
-            build_single(RACK_BUILD_DIR, RACK_BUILD_TARGET_DIR, dir_file, config_var)
+            build_single(RACK_BUILD_DIR, rackBuildDirFull, dir_file, config_var)
 
         for dir_file in os.listdir(RACK_MOUNT_BUILD_DIR):
-            build_single(RACK_MOUNT_BUILD_DIR, RACK_MOUNT_BUILD_TARGET_DIR, dir_file, config_var)
-
+            build_single(RACK_MOUNT_BUILD_DIR, rackMountBuildDirFull, dir_file, config_var)
         return
 
     filename_rack = find_rack(build_var)
@@ -75,10 +85,10 @@ def run_build(build_var, config_var):
         return
 
     if filename_rack:
-        build_single(RACK_BUILD_DIR, RACK_BUILD_TARGET_DIR, filename_rack, config_var)
+        build_single(RACK_BUILD_DIR, rackBuildDirFull, filename_rack, config_var)
 
     if filename_rack_mount:
-        build_single(RACK_MOUNT_BUILD_DIR, RACK_MOUNT_BUILD_TARGET_DIR, filename_rack, config_var)
+        build_single(RACK_MOUNT_BUILD_DIR, rackMountBuildDirFull, filename_rack, config_var)
 
 
 def build_single(build_dir, target_dir, filename, config):
@@ -86,14 +96,12 @@ def build_single(build_dir, target_dir, filename, config):
     openscad_args = construct_openscad_args(build_dir, target_dir, filename, config)
     run_openscad(openscad_args)
 
-    convert_text_stl_to_binary(openscad_args[1])
-
 
 def construct_openscad_args(build_dir, target_dir, filename, config):
     source = os.path.join(build_dir, filename)
     target = os.path.join(target_dir, os.path.splitext(filename)[0] + '.stl')
 
-    return ['-o', target, source]
+    return ['-D', 'profileName=\"' + config + '\"', '-o', target, source]
 
 
 def find_rack(filename):
@@ -121,24 +129,15 @@ def find_scad_file(directory, filename):
     return None
 
 
-def run_openscad(options=['-h']):
-    command = ['openscad', '-q'] + options
+def run_openscad(options):
+    command = ['openscad', '-q', '--export-format', 'binstl'] + options
     try:
         subprocess.check_output(command, universal_newlines=True, stderr=subprocess.DEVNULL)
 
     except FileNotFoundError:
         print('OpenSCAD command not found! '
               'Please make sure that you have OpenSCAD installed and can run OpenSCAD CLI commands. '
-              '(Currently need Linux for this)')
-
-
-def convert_text_stl_to_binary(file_path):
-    mesh_data = mesh.Mesh.from_file(file_path)
-
-    # Remove the original file
-    os.remove(file_path)
-
-    mesh_data.save(file_path, mode=stl.Mode.BINARY)
+              '(Currently needs Linux for this)')
 
 
 def assert_os():