Redesigned Z axis to fix lifter binding issues.

GDMUtils.scad

@@ -557,13 +557,16 @@ module angle_pie_mask(
 }
 
 
-// Creates a shape that can be used to chamfer a 90 degree edge.
+// Creates a shape that can be used to chamfer a 90 degree vertical edge.
 // Difference it from the object to be chamfered.  The center of the mask
 // object should align exactly with the edge to be chamfered.
 module chamfer_mask(h=1.0, r=1.0)
 {
 	zrot(45) cube(size=[r*sqrt(2.0), r*sqrt(2.0), h], center=true);
 }
+module chamfer_mask_x(l=1.0, chamfer=1.0) {yrot(90) chamfer_mask(h=l, r=chamfer);}
+module chamfer_mask_y(l=1.0, chamfer=1.0) {xrot(90) chamfer_mask(h=l, r=chamfer);}
+module chamfer_mask_z(l=1.0, chamfer=1.0) {chamfer_mask(h=l, r=chamfer);}
 
 
 // Chamfers the edges of a cuboid region containing the given children.
@@ -581,49 +584,44 @@ module chamfer_mask(h=1.0, r=1.0)
 //   }
 module chamfer(chamfer=1, size=[1,1,1], edges=[[0,0,0,0], [1,1,0,0], [0,0,0,0]])
 {
+	eps = 0.1;
+	x = size[0];
+	y = size[1];
+	z = size[2];
+	lx = x + eps;
+	ly = y + eps;
+	lz = z + eps;
 	difference() {
 		union() {
 			children();
 		}
 		union() {
 			if (edges[0][0] != 0)
-				translate([0,  size[1]/2,  size[2]/2])
-					xrot(45) cube(size=[size[0]+0.1, chamfer*sqrt(2), chamfer*sqrt(2)], center=true);
+				up(z/2) back(y/2) chamfer_mask_x(l=lx, chamfer=chamfer);
 			if (edges[0][1] != 0)
-				translate([0, -size[1]/2,  size[2]/2])
-					xrot(45) cube(size=[size[0]+0.1, chamfer*sqrt(2), chamfer*sqrt(2)], center=true);
+				up(z/2) fwd(y/2) chamfer_mask_x(l=lx, chamfer=chamfer);
 			if (edges[0][2] != 0)
-				translate([0,  size[1]/2, -size[2]/2])
-					xrot(45) cube(size=[size[0]+0.1, chamfer*sqrt(2), chamfer*sqrt(2)], center=true);
+				down(z/2) back(y/2) chamfer_mask_x(l=lx, chamfer=chamfer);
 			if (edges[0][3] != 0)
-				translate([0, -size[1]/2, -size[2]/2])
-					xrot(45) cube(size=[size[0]+0.1, chamfer*sqrt(2), chamfer*sqrt(2)], center=true);
+				down(z/2) fwd(y/2) chamfer_mask_x(l=lx, chamfer=chamfer);
 
 			if (edges[1][0] != 0)
-				translate([ size[0]/2, 0,  size[2]/2])
-					yrot(45) cube(size=[chamfer*sqrt(2), size[1]+0.1, chamfer*sqrt(2)], center=true);
+				up(z/2) right(x/2) chamfer_mask_y(l=ly, chamfer=chamfer);
 			if (edges[1][1] != 0)
-				translate([-size[0]/2, 0,  size[2]/2])
-					yrot(45) cube(size=[chamfer*sqrt(2), size[1]+0.1, chamfer*sqrt(2)], center=true);
+				up(z/2) left(x/2) chamfer_mask_y(l=ly, chamfer=chamfer);
 			if (edges[1][2] != 0)
-				translate([ size[0]/2, 0, -size[2]/2])
-					yrot(45) cube(size=[chamfer*sqrt(2), size[1]+0.1, chamfer*sqrt(2)], center=true);
+				down(z/2) right(x/2) chamfer_mask_y(l=ly, chamfer=chamfer);
 			if (edges[1][3] != 0)
-				translate([-size[0]/2, 0, -size[2]/2])
-					yrot(45) cube(size=[chamfer*sqrt(2), size[1]+0.1, chamfer*sqrt(2)], center=true);
+				down(z/2) left(x/2) chamfer_mask_y(l=ly, chamfer=chamfer);
 
 			if (edges[2][0] != 0)
-				translate([ size[0]/2,  size[1]/2, 0])
-					zrot(45) cube(size=[chamfer*sqrt(2), chamfer*sqrt(2), size[2]+0.1], center=true);
+				back(y/2) right(x/2) chamfer_mask_z(l=lz, chamfer=chamfer);
 			if (edges[2][1] != 0)
-				translate([-size[0]/2,  size[1]/2, 0])
-					zrot(45) cube(size=[chamfer*sqrt(2), chamfer*sqrt(2), size[2]+0.1], center=true);
+				back(y/2) left(x/2) chamfer_mask_z(l=lz, chamfer=chamfer);
 			if (edges[2][2] != 0)
-				translate([ size[0]/2, -size[1]/2, 0])
-					zrot(45) cube(size=[chamfer*sqrt(2), chamfer*sqrt(2), size[2]+0.1], center=true);
+				fwd(y/2) right(x/2) chamfer_mask_z(l=lz, chamfer=chamfer);
 			if (edges[2][3] != 0)
-				translate([-size[0]/2, -size[1]/2, 0])
-					zrot(45) cube(size=[chamfer*sqrt(2), chamfer*sqrt(2), size[2]+0.1], center=true);
+				fwd(y/2) left(x/2) chamfer_mask_z(l=lz, chamfer=chamfer);
 		}
 	}
 }
@@ -1334,10 +1332,128 @@ module narrowing_strut(w=10, l=100, wall=5, ang=30)
 //   ang = maximum overhang angle of diagonal brace.
 //   strut = the width of the diagonal brace.
 //   wall = the thickness of the thinned portion of the wall.
-//   bracing = boolean, denoting that the wall should have diagonal cross-braces.
 // Example:
 //   thinning_wall(h=50, l=100, thick=4, ang=30, strut=5, wall=2);
-module thinning_wall(h=50, l=100, thick=5, ang=30, strut=5, wall=2, bracing=true)
+module thinning_wall(h=50, l=100, thick=5, ang=30, strut=5, wall=2)
+{
+	l1 = (l[0] == undef)? l : l[0];
+	l2 = (l[1] == undef)? l : l[1];
+
+	trap_ang = atan2((l2-l1)/2, h);
+	corr1 = 1 + sin(trap_ang);
+	corr2 = 1 - sin(trap_ang);
+
+	z1 = h/2;
+	z2 = max(0.1, z1 - strut);
+	z3 = max(0.05, z2 - (thick-wall)/2*sin(90-ang)/sin(ang));
+
+	x1 = l2/2;
+	x2 = max(0.1, x1 - strut*corr1);
+	x3 = max(0.05, x2 - (thick-wall)/2*sin(90-ang)/sin(ang)*corr1);
+	x4 = l1/2;
+	x5 = max(0.1, x4 - strut*corr2);
+	x6 = max(0.05, x5 - (thick-wall)/2*sin(90-ang)/sin(ang)*corr2);
+
+	y1 = thick/2;
+	y2 = y1 - min(z2-z3, x2-x3) * sin(ang);
+
+	zrot(90)
+	polyhedron(
+		points=[
+			[-x4, -y1, -z1],
+			[ x4, -y1, -z1],
+			[ x1, -y1,  z1],
+			[-x1, -y1,  z1],
+
+			[-x5, -y1, -z2],
+			[ x5, -y1, -z2],
+			[ x2, -y1,  z2],
+			[-x2, -y1,  z2],
+
+			[-x6, -y2, -z3],
+			[ x6, -y2, -z3],
+			[ x3, -y2,  z3],
+			[-x3, -y2,  z3],
+
+			[-x4,  y1, -z1],
+			[ x4,  y1, -z1],
+			[ x1,  y1,  z1],
+			[-x1,  y1,  z1],
+
+			[-x5,  y1, -z2],
+			[ x5,  y1, -z2],
+			[ x2,  y1,  z2],
+			[-x2,  y1,  z2],
+
+			[-x6,  y2, -z3],
+			[ x6,  y2, -z3],
+			[ x3,  y2,  z3],
+			[-x3,  y2,  z3],
+		],
+		faces=[
+			[ 4,  5,  1],
+			[ 5,  6,  2],
+			[ 6,  7,  3],
+			[ 7,  4,  0],
+
+			[ 4,  1,  0],
+			[ 5,  2,  1],
+			[ 6,  3,  2],
+			[ 7,  0,  3],
+
+			[ 8,  9,  5],
+			[ 9, 10,  6],
+			[10, 11,  7],
+			[11,  8,  4],
+
+			[ 8,  5,  4],
+			[ 9,  6,  5],
+			[10,  7,  6],
+			[11,  4,  7],
+
+			[11, 10,  9],
+			[20, 21, 22],
+
+			[11,  9,  8],
+			[20, 22, 23],
+
+			[16, 17, 21],
+			[17, 18, 22],
+			[18, 19, 23],
+			[19, 16, 20],
+
+			[16, 21, 20],
+			[17, 22, 21],
+			[18, 23, 22],
+			[19, 20, 23],
+
+			[12, 13, 17],
+			[13, 14, 18],
+			[14, 15, 19],
+			[15, 12, 16],
+
+			[12, 17, 16],
+			[13, 18, 17],
+			[14, 19, 18],
+			[15, 16, 19],
+
+			[ 0,  1, 13],
+			[ 1,  2, 14],
+			[ 2,  3, 15],
+			[ 3,  0, 12],
+
+			[ 0, 13, 12],
+			[ 1, 14, 13],
+			[ 2, 15, 14],
+			[ 3, 12, 15],
+		],
+		convexity=2
+	);
+}
+//!thinning_wall(h=50, l=[100, 80], thick=4, ang=30, strut=5, wall=2);
+
+
+module braced_thinning_wall(h=50, l=100, thick=5, ang=30, strut=5, wall=2)
 {
 	dang = atan((h-2*strut)/(l-2*strut));
 	dlen = (h-2*strut)/sin(dang);
@@ -1345,17 +1461,15 @@ module thinning_wall(h=50, l=100, thick=5, ang=30, strut=5, wall=2, bracing=true
 		xrot_copies([0, 180]) {
 			down(h/2) narrowing_strut(w=thick, l=l, wall=strut, ang=ang);
 			fwd(l/2) xrot(-90) narrowing_strut(w=thick, l=h-0.1, wall=strut, ang=ang);
-			if (bracing == true) {
-				intersection() {
-					cube(size=[thick, l, h], center=true);
-					xrot_copies([-dang,dang]) {
-						zspread(strut/2) {
-							scale([1,1,1.5]) yrot(45) {
-								cube(size=[thick/sqrt(2), dlen, thick/sqrt(2)], center=true);
-							}
+			intersection() {
+				cube(size=[thick, l, h], center=true);
+				xrot_copies([-dang,dang]) {
+					zspread(strut/2) {
+						scale([1,1,1.5]) yrot(45) {
+							cube(size=[thick/sqrt(2), dlen, thick/sqrt(2)], center=true);
 						}
-						cube(size=[thick, dlen, strut/2], center=true);
 					}
+					cube(size=[thick, dlen, strut/2], center=true);
 				}
 			}
 		}
@@ -1421,6 +1535,62 @@ module thinning_brace(h=50, l=100, thick=5, ang=30, strut=5, wall=3)
 }
 
 
+// Makes an open rectangular strut with X-shaped cross-bracing, designed with 3D printing in mind.
+//   h = Z size of strut.
+//   w = X size of strut.
+//   l = Y size of strut.
+//   thick = thickness of strut walls.
+//   maxang = maximum overhang angle of cross-braces.
+//   max_bridge = maximum bridging distance between cross-braces.
+//   strut = the width of the cross-braces.
+// Example:
+//   sparse_strut3d(h=40, w=40, l=120, thick=4, maxang=30, strut=5, max_bridge=20);
+module sparse_strut3d(h=50, l=100, w=50, thick=3, maxang=40, strut=3, max_bridge = 20)
+{
+
+	xoff = w - thick;
+	yoff = l - thick;
+	zoff = h - thick;
+
+	xreps = ceil(xoff/yoff);
+	yreps = ceil(yoff/xoff);
+
+	xstep = xoff / xreps;
+	ystep = yoff / yreps;
+
+	cross_ang = atan2(xstep, ystep);
+	cross_len = hypot(xstep, ystep);
+
+	union() {
+		if(xreps>1) {
+			yspread(yoff) {
+				xspread(xstep, n=xreps-1) {
+					cube(size=[thick, thick, h], center=true);
+				}
+			}
+		}
+		if(yreps>1) {
+			xspread(xoff) {
+				yspread(ystep, n=yreps-1) {
+					cube(size=[thick, thick, h], center=true);
+				}
+			}
+		}
+		xspread(xoff) sparse_strut(h=h, l=l, thick=thick, maxang=maxang, strut=strut, max_bridge=max_bridge);
+		yspread(yoff) zrot(90) sparse_strut(h=h, l=w, thick=thick, maxang=maxang, strut=strut, max_bridge=max_bridge);
+		for(xs = [0:xreps-1]) {
+			for(ys = [0:yreps-1]) {
+				translate([(xs+0.5)*xstep-xoff/2, (ys+0.5)*ystep-yoff/2, 0]) {
+					zrot( cross_ang) sparse_strut(h=h, l=cross_len, thick=thick, maxang=maxang, strut=strut, max_bridge=max_bridge);
+					zrot(-cross_ang) sparse_strut(h=h, l=cross_len, thick=thick, maxang=maxang, strut=strut, max_bridge=max_bridge);
+				}
+			}
+		}
+	}
+}
+//!sparse_strut3d(h=40, w=40, l=120, thick=3, strut=3);
+
+
 // Makes an open rectangular strut with X-shaped cross-bracing, designed with 3D printing in mind.
 //   h = height of strut wall.
 //   l = length of strut wall.

STLs/rail_y_endcap_parts.stl

@@ -20,13 +20,6 @@ solid Model
       vertex -0.0144 -56.675 0
     endloop
   endfacet
-  facet normal -1 0 0
-    outer loop
-      vertex -40 -60 0
-      vertex -40 -55 0
-      vertex -40 50 0
-    endloop
-  endfacet
   facet normal 0 0 -1
     outer loop
       vertex -40 -60 0
@@ -48,13 +41,6 @@ solid Model
       vertex -0.0289 -47.5 0
     endloop
   endfacet
-  facet normal -1 0 0
-    outer loop
-      vertex -40 -55 0
-      vertex -40 0 0
-      vertex -40 50 0
-    endloop
-  endfacet
   facet normal 0 0 -1
     outer loop
       vertex -0.0144 -53.325 0
@@ -181,6 +167,13 @@ solid Model
       vertex -0.0029 60 0
     endloop
   endfacet
+  facet normal -1 0 0
+    outer loop
+      vertex -40 -60 0
+      vertex -40 -50 5
+      vertex -40 50 0
+    endloop
+  endfacet
   facet normal 0 1 0
     outer loop
       vertex -0.0289 -50 0
@@ -209,13 +202,6 @@ solid Model
       vertex 0 -47.5 5
     endloop
   endfacet
-  facet normal -1 0 0
-    outer loop
-      vertex -40 0 0
-      vertex -40 50 5
-      vertex -40 50 0
-    endloop
-  endfacet
   facet normal 0 1 0
     outer loop
       vertex -0.0289 47.5 0
@@ -328,13 +314,6 @@ solid Model
       vertex -5.2953 56.4167 9.1667
     endloop
   endfacet
-  facet normal -1 0 0
-    outer loop
-      vertex -40 -55 0
-      vertex -40 -45 10
-      vertex -40 0 0
-    endloop
-  endfacet
   facet normal 0 -1 0
     outer loop
       vertex -40 -60 0
@@ -342,13 +321,6 @@ solid Model
       vertex -0.0029 -60 25
     endloop
   endfacet
-  facet normal -1 0 0
-    outer loop
-      vertex -40 -60 0
-      vertex -40 -55 61.95
-      vertex -40 -55 0
-    endloop
-  endfacet
   facet normal 0.866 0 0.5
     outer loop
       vertex -0.0289 -47.5 0
@@ -356,6 +328,13 @@ solid Model
       vertex -2.9156 -50 5
     endloop
   endfacet
+  facet normal -1 0 0
+    outer loop
+      vertex -40 50 0
+      vertex -40 -50 5
+      vertex -40 50 5
+    endloop
+  endfacet
   facet normal 0 -1 0
     outer loop
       vertex -0.0289 -47.5 0
@@ -370,13 +349,6 @@ solid Model
       vertex 0 -47.5 5
     endloop
   endfacet
-  facet normal -1 0 0
-    outer loop
-      vertex -40 0 0
-      vertex -40 0 5
-      vertex -40 50 5
-    endloop
-  endfacet
   facet normal 0 1 0
     outer loop
       vertex -0.0289 47.5 0
@@ -428,9 +400,9 @@ solid Model
   endfacet
   facet normal -1 0 0
     outer loop
-      vertex -40 0 0
-      vertex -40 -45 10
-      vertex -40 0 5
+      vertex -40 -60 0
+      vertex -40 -60 61.995
+      vertex -40 -50 5
     endloop
   endfacet
   facet normal 0 1 0
@@ -594,13 +566,6 @@ solid Model
       vertex 5.2924 -60 15.8333
     endloop
   endfacet
-  facet normal -1 0 0
-    outer loop
-      vertex -40 -55 0
-      vertex -40 -45 52
-      vertex -40 -45 10
-    endloop
-  endfacet
   facet normal 0 -1 0
     outer loop
       vertex 0 -60 0
@@ -622,20 +587,6 @@ solid Model
       vertex -40 -60 61.995
     endloop
   endfacet
-  facet normal -1 0 0
-    outer loop
-      vertex -40 -55 0
-      vertex -40 -55 61.95
-      vertex -40 -45 52
-    endloop
-  endfacet
-  facet normal -1 0 0
-    outer loop
-      vertex -40 -60 0
-      vertex -40 -60 61.995
-      vertex -40 -55 61.95
-    endloop
-  endfacet
   facet normal 0 0 1
     outer loop
       vertex -35 -50 5
@@ -647,7 +598,14 @@ solid Model
     outer loop
       vertex -35 -50 5
       vertex -2.9156 -47.5 5
-      vertex -35 50 5
+      vertex -35 5 5
+    endloop
+  endfacet
+  facet normal 0 0 0
+    outer loop
+      vertex -40 -50 5
+      vertex -40 -5 5
+      vertex -40 50 5
     endloop
   endfacet
   facet normal 0 0 1
@@ -657,6 +615,13 @@ solid Model
       vertex -2.9156 47.5 5
     endloop
   endfacet
+  facet normal 0 0 1
+    outer loop
+      vertex -2.9156 -47.5 5
+      vertex -2.9156 47.5 5
+      vertex -35 5 5
+    endloop
+  endfacet
   facet normal 0 0 1
     outer loop
       vertex 0 -47.5 5
@@ -666,7 +631,7 @@ solid Model
   endfacet
   facet normal 0 0 1
     outer loop
-      vertex -2.9156 -47.5 5
+      vertex -35 5 5
       vertex -2.9156 47.5 5
       vertex -35 50 5
     endloop
@@ -692,20 +657,34 @@ solid Model
       vertex -2.9156 60 5
     endloop
   endfacet
+  facet normal -1 0 0
+    outer loop
+      vertex -40 -50 5
+      vertex -40 -45 10
+      vertex -40 -5 5
+    endloop
+  endfacet
   facet normal 1 0 0
     outer loop
       vertex -35 -50 5
-      vertex -35 50 5
+      vertex -35 5 5
       vertex -35 -45 10
     endloop
   endfacet
   facet normal -1 0 0
     outer loop
-      vertex -40 0 5
+      vertex -40 -5 5
       vertex -40 45 10
       vertex -40 50 5
     endloop
   endfacet
+  facet normal 1 0 0
+    outer loop
+      vertex -35 5 5
+      vertex -35 50 5
+      vertex -35 45 10
+    endloop
+  endfacet
   facet normal 0 1 0
     outer loop
       vertex -35 -50 5
@@ -743,14 +722,14 @@ solid Model
   endfacet
   facet normal -1 0 0
     outer loop
-      vertex -40 0 5
+      vertex -40 -5 5
       vertex -40 -45 10
       vertex -40 45 10
     endloop
   endfacet
   facet normal 1 0 0
     outer loop
-      vertex -35 50 5
+      vertex -35 5 5
       vertex -35 45 10
       vertex -35 -45 10
     endloop
@@ -773,7 +752,14 @@ solid Model
     outer loop
       vertex -35 -50 5
       vertex -35 -45 10
-      vertex -35 -45 52
+      vertex -35 -50 57
+    endloop
+  endfacet
+  facet normal -1 0 0
+    outer loop
+      vertex -40 -50 5
+      vertex -40 -60 61.995
+      vertex -40 -45 10
     endloop
   endfacet
   facet normal 0 1 0
@@ -807,7 +793,7 @@ solid Model
   facet normal 0 1 0
     outer loop
       vertex -35 -50 5
-      vertex -35 -50 61.995
+      vertex -35 -50 57
       vertex -5.2953 -50 34.1667
     endloop
   endfacet
@@ -818,13 +804,6 @@ solid Model
       vertex -40 60 50
     endloop
   endfacet
-  facet normal 1 0 0
-    outer loop
-      vertex -35 -50 5
-      vertex -35 -45 52
-      vertex -35 -50 61.995
-    endloop
-  endfacet
   facet normal 0 0 1
     outer loop
       vertex 0 -57.0938 5.2687
@@ -1308,74 +1287,74 @@ solid Model
       vertex -5.2953 57.6667 12.5
     endloop
   endfacet
-  facet normal -0.866 0 0.5
-    outer loop
-      vertex -40 -45 10
-      vertex -38.5 -42.4019 12.5981
-      vertex -40 45 10
-    endloop
-  endfacet
-  facet normal 0.866 0 0.5
+  facet normal 0.8944 0 0.4472
     outer loop
       vertex -35 -45 10
       vertex -35 45 10
-      vertex -36.5 -42.4019 12.5981
+      vertex -36.299 -42.4019 12.5981
     endloop
   endfacet
-  facet normal -0.866 0 0.5
-    outer loop
-      vertex -40 45 10
-      vertex -38.5 -42.4019 12.5981
-      vertex -38.5 42.4019 12.5981
-    endloop
-  endfacet
-  facet normal 0.866 0 0.5
-    outer loop
-      vertex -35 45 10
-      vertex -36.5 42.4019 12.5981
-      vertex -36.5 -42.4019 12.5981
-    endloop
-  endfacet
-  facet normal -0.866 0.5 0
+  facet normal -0.8944 0 0.4472
     outer loop
       vertex -40 -45 10
-      vertex -38.5 -42.4019 49.4019
-      vertex -38.5 -42.4019 12.5981
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bridge_segment_parts.scad

@@ -0,0 +1,165 @@
+include <config.scad>
+use <GDMUtils.scad>
+use <joiners.scad>
+
+$fa=2;
+$fs=2;
+
+// connectby valid options: "", "fwd", "back"
+module bridge_segment(explode=0, connectby="")
+{
+	side_joiner_len = 2;
+	l = rail_length - 2 * printer_slop;
+	spacing = z_joiner_spacing;
+
+	up(
+		(connectby=="fwd")? -rail_height/2 :
+		(connectby=="back")? -rail_height/2 :
+		0
+	) back(
+		(connectby=="back")? -l/2 :
+		(connectby=="fwd")? l/2 :
+		0
+	) {
+		color([0.9, 0.7, 1.0])
+		prerender(convexity=20)
+		union() {
+			difference() {
+				union() {
+					// Bottom.
+					up(rail_thick/2) yrot(90)
+						sparse_strut(h=spacing, l=l-1, thick=rail_thick, maxang=70, strut=7, max_bridge=500);
+
+					// Screw rack
+					ang = acos(1 - 2*lifter_tooth_depth/lifter_screw_diam);
+					teeth_h = sin(ang) * lifter_screw_diam + 6;
+					xspread(spacing) {
+						up(rail_height/2) {
+							difference() {
+								union() {
+									if (wall_style == "crossbeams")
+										sparse_strut(h=rail_height, l=l-0.1, thick=2.0*lifter_tooth_depth, strut=platform_thick);
+									if (wall_style == "thinwall")
+										thinning_wall(h=rail_height, l=l-0.1, thick=2.0*lifter_tooth_depth, strut=platform_thick);
+									if (wall_style == "corrugated") {
+										corrugated_wall(h=rail_height, l=l-0.1, thick=2.0*lifter_tooth_depth, strut=platform_thick);
+
+										// Side wiring access hole frame
+										down(rail_height/2-10/2-rail_thick) {
+											yspread(motor_rail_length-2*28) {
+												cube(size=[platform_thick, 16+4, 10+4], center=true);
+											}
+										}
+									}
+								}
+
+								// Side wiring access hole
+								if (wall_style != "crossbeams") {
+									down(rail_height/2-10/2-rail_thick) {
+										yspread(motor_rail_length-2*28) {
+											cube(size=[10, 16, 10], center=true);
+										}
+									}
+								}
+							}
+						}
+					}
+
+					// Side Supports
+					up(rail_height/2) {
+						yspread((l-2*5-5)/2, n=3) {
+							difference() {
+								cube(size=[spacing, 4, rail_height], center=true);
+								down(rail_height/2-rail_thick-10/2) cube(size=[16, 11, 10], center=true);
+							}
+						}
+					}
+
+				}
+
+				// Clear space for joiners.
+				up(rail_height/2) {
+					fwd(l/2-0.05) zrot(180) xspread(spacing) joiner_clear(h=rail_height, w=joiner_width, clearance=1, a=joiner_angle);
+					back(l/2-0.05) xspread(spacing) yrot(180) joiner_clear(h=rail_height, w=joiner_width, clearance=1, a=joiner_angle);
+				}
+			}
+
+			difference() {
+				// Snap-tab joiners.
+				up(rail_height/2+0.05) {
+					fwd(l/2) zrot(180) xspread(spacing) joiner(h=rail_height, w=joiner_width, l=10, a=joiner_angle);
+					back(l/2) xspread(spacing) yrot(180) joiner(h=rail_height, w=joiner_width, l=10, a=joiner_angle);
+				}
+
+				// Clear space for Side half joiners
+				up(rail_height/2/2) {
+					yspread(l-2*joiner_width-1-0.05) {
+						zring(r=spacing/2+joiner_width/2+side_joiner_len+0.05, n=2) {
+							zrot(-90) {
+								chamfer(chamfer=3, size=[joiner_width, 2*(side_joiner_len+joiner_width/2), rail_height/2], edges=[[0,0,0,0], [1,1,0,0], [0,0,0,0]]) {
+									half_joiner_clear(h=rail_height/2, w=joiner_width, a=joiner_angle, clearance=0);
+								}
+							}
+						}
+					}
+				}
+			}
+
+			// Side half joiners
+			up(rail_height/2/2) {
+				yspread(l-2*joiner_width-1-0.05) {
+					zring(r=spacing/2+joiner_width/2+side_joiner_len+0.1, n=2) {
+						zrot(-90) {
+							chamfer(chamfer=3, size=[joiner_width, 2*(side_joiner_len+joiner_width/2), rail_height/2], edges=[[0,0,0,0], [1,1,0,0], [0,0,0,0]]) {
+								half_joiner2(h=rail_height/2, w=joiner_width, l=side_joiner_len+joiner_width/2, a=joiner_angle);
+							}
+						}
+					}
+				}
+			}
+		}
+
+		up(rail_height/2) {
+			fwd(l/2+explode) {
+				if ($children > 0) children(0);
+			}
+			back(l/2+explode) {
+				if ($children > 1) children(1);
+			}
+		}
+		up(rail_height/2/2) {
+			back(l/2-10) {
+				left(spacing/2+joiner_width/2+side_joiner_len) {
+					if ($children > 2) children(2);
+				}
+				right(spacing/2+joiner_width/2+side_joiner_len) {
+					if ($children > 3) children(3);
+				}
+			}
+			fwd(l/2-10) {
+				left(spacing/2+joiner_width/2+side_joiner_len) {
+					if ($children > 4) children(4);
+				}
+				right(spacing/2+joiner_width/2+side_joiner_len) {
+					if ($children > 5) children(5);
+				}
+			}
+		}
+	}
+}
+//!bridge_segment();
+
+
+
+module bridge_segment_parts() { // make me
+	bridge_segment();
+}
+
+
+
+bridge_segment_parts();
+
+
+
+// vim: noexpandtab tabstop=4 shiftwidth=4 softtabstop=4 nowrap
+

cable_chain.scad

@@ -12,12 +12,9 @@ module cable_chain_barrel()
 	color("SpringGreen")
 	union () {
 		difference() {
-			translate([0, 0, h/2])
-				cube(size=[w, l-20, h], center=true);
-			translate([0, 0, h/2])
-				chamfcube(size=[w-4*cable_chain_wall, l, h-cable_chain_wall], chamfer=2, center=true);
-			zrot(40)
-				cube(size=[2, (l-15)/cos(40), 2*cable_chain_wall], center=true);
+			up(h/2) cube(size=[w, l-20, h], center=true);
+			up(h/2-2/2) chamfcube(size=[w-4*cable_chain_wall, l, h-cable_chain_wall-2], chamfer=2, center=true);
+			zrot(40) cube(size=[2, (l-15)/cos(40), 2*cable_chain_wall], center=true);
 		}
 	}
 }

config.scad

@@ -37,7 +37,7 @@ motor_shaft_flatted = true;  // Is motor shaft keyed? (RECOMMENDED)
 
 // Currently configured for 3/8" ACME threaded rod.
 lifter_screw_diam   = 60.0; // mm
-lifter_screw_thick  = 12.0; // mm
+lifter_screw_thick  = 20.0; // mm
 lifter_screw_pitch  =  8.0; // mm lift per revolution
 lifter_screw_angle  = 50.0; // degrees tooth face angle
 
@@ -64,7 +64,7 @@ glass_length    = 200;   // mm
 glass_thick     =   3;   // mm
 
 // Cable chain dimensions
-cable_chain_height = 13;  // mm
+cable_chain_height = 15;  // mm
 cable_chain_width  = 25;  // mm
 cable_chain_length = 26;  // mm
 cable_chain_pivot  =  6;  // mm
@@ -124,7 +124,7 @@ gear_backlash = printer_slop/2;
 
 
 // Commonly used derived values.  Don't change these.
-extruder_length = motor_rail_length;
+extruder_length = motor_rail_length + 2*lifter_screw_pitch;
 shaft_clear = max(20.0, motor_shaft_length)-20.0;
 rail_offset = shaft_clear+12.0;
 rail_spacing = platform_width - joiner_width*4 - 10;
@@ -134,6 +134,9 @@ side_mount_spacing = motor_rail_length-10*2;
 platform_z = rail_height+groove_height+rail_offset;
 cantilever_length = (motor_rail_length+2*platform_length-2*rail_height-extruder_length-groove_height)/2;
 motor_top_z = platform_z-platform_thick-rack_base-rack_height-gear_base-2;
+lifter_tooth_depth = lifter_screw_pitch / 3.2;
+z_joiner_spacing = lifter_screw_diam + 2*lifter_tooth_depth + joiner_width;
+z_base_height = rail_height + groove_height + 2*platform_thick;
 
 wall_styles = ["thinwall", "corrugated", "crossbeams"];
 wall_style = wall_styles[wall_styling];

docs/assembly/index.html

@@ -149,7 +149,7 @@ UL {
 <li class="section"><h2>Z Tower Assembly</h2>
 <ul>
 <li class="step"><h3>Step 1</h3>
-<div class="desc">Attach three Z rail segments together to make a Z tower rail assembly.  Do this again to make a second 3 segment tower. (Six total Z-rail segments in two sets of three.)  Apply mineral oil to the slider rails, and the lifter screw grooves, for lubrication.</div>
+<div class="desc">Attach two Z rail segments together to make a Z tower rail assembly.  Do this again to make a second tower. Superglue these together if they aren't attached firmly.  Lubricate the slider rails and lifter screw slots with mineral oil.</div>
 <table><tr><td class="befor"><img src="z_tower_assembly_1_before.png"></td><td class="arrow"><img src="arrow.png"></td><td class="after"><img src="z_tower_assembly_1_after.png"></td></tr></table>
 </li>
 <li class="step"><h3>Step 2</h3>
@@ -157,13 +157,17 @@ UL {
 <table><tr><td class="befor"><img src="z_tower_assembly_2_before.png"></td><td class="arrow"><img src="arrow.png"></td><td class="after"><img src="z_tower_assembly_2_after.png"></td></tr></table>
 </li>
 <li class="step"><h3>Step 3</h3>
-<div class="desc">Attach a Z tower rail assembly to the top of each YZ joiner assembly.</div>
+<div class="desc">Attach a Z base part to the top of each YZ joiner assembly, to make two tower base assemblies. Superglue these together if the attachment is wobbly in any way.</div>
 <table><tr><td class="befor"><img src="z_tower_assembly_3_before.png"></td><td class="arrow"><img src="arrow.png"></td><td class="after"><img src="z_tower_assembly_3_after.png"></td></tr></table>
 </li>
 <li class="step"><h3>Step 4</h3>
-<div class="desc">Attach a cable chain joiner mount to the front-size of the left Z tower, above the top hole of the bottom rail segment.</div>
+<div class="desc">Attach a Z tower rail assembly to the top of each tower base assembly.  Superglue these together if the attachment is wobbly in any way.</div>
 <table><tr><td class="befor"><img src="z_tower_assembly_4_before.png"></td><td class="arrow"><img src="arrow.png"></td><td class="after"><img src="z_tower_assembly_4_after.png"></td></tr></table>
 </li>
+<li class="step"><h3>Step 5</h3>
+<div class="desc">Attach a cable chain joiner mount to the front-size of the left Z tower, above the top hole of the bottom rail segment.</div>
+<table><tr><td class="befor"><img src="z_tower_assembly_5_before.png"></td><td class="arrow"><img src="arrow.png"></td><td class="after"><img src="z_tower_assembly_5_after.png"></td></tr></table>
+</li>
 </ul>
 </li>
 <li class="section"><h2>Extruder Assembly</h2>
@@ -217,7 +221,7 @@ UL {
 <li class="section"><h2>Bridge Assembly</h2>
 <ul>
 <li class="step"><h3>Step 1</h3>
-<div class="desc">Attach rail segments to either end of the extruder platform assembly.  Route the wiring through the left side rail segment, and out the front-left wiring access hole.</div>
+<div class="desc">Attach bridge segments to either end of the extruder platform assembly.  Superglue these together if the attachments are in any way wobbly.  Route the wiring through the left side bridge segment, and out the front-left wiring access hole.</div>
 <table><tr><td class="befor"><img src="bridge_assembly_1_before.png"></td><td class="arrow"><img src="arrow.png"></td><td class="after"><img src="bridge_assembly_1_after.png"></td></tr></table>
 </li>
 <li class="step"><h3>Step 2</h3>
@@ -225,7 +229,7 @@ UL {
 <table><tr><td class="befor"><img src="bridge_assembly_2_before.png"></td><td class="arrow"><img src="arrow.png"></td><td class="after"><img src="bridge_assembly_2_after.png"></td></tr></table>
 </li>
 <li class="step"><h3>Step 3</h3>
-<div class="desc">Attach Z sled segments to either end of the extruder bridge assembly.</div>
+<div class="desc">Attach Z sled segments to either end of the extruder bridge assembly.  Superglue these on if the attachments are in any way wobbly.</div>
 <table><tr><td class="befor"><img src="bridge_assembly_3_before.png"></td><td class="arrow"><img src="arrow.png"></td><td class="after"><img src="bridge_assembly_3_after.png"></td></tr></table>
 </li>
 <li class="step"><h3>Step 4</h3>