Initial Snappy3 redesign.

GDMUtils.scad

@@ -818,7 +818,7 @@ module fillet_hole_mask(r=1.0, fillet=0.25, xtilt=0, ytilt=0)
 
 
 // For when you MUST pass a child to a module, but you want it to be nothing.
-module nil() difference() {cube(0.1, center=true); cube(0.2, center=true);}
+module nil() union();
 
 
 // Makes a cube that is centered in X and Y axes, and has its bottom aligned with Z=0.
@@ -1085,9 +1085,12 @@ module right_triangle(size=[1, 1, 1], center=false)
 			],
 			faces=[
 				[0, 1, 2],
-				[0, 2, 5, 3],
-				[0, 3, 4, 1],
-				[1, 4, 5, 2],
+				[0, 2, 5],
+				[0, 5, 3],
+				[0, 3, 4],
+				[0, 4, 1],
+				[1, 4, 5],
+				[1, 5, 2],
 				[3, 5, 4]
 			],
 			convexity=2

Makefile

@@ -1,6 +1,6 @@
 OPENSCAD=/Applications/OpenSCAD.app/Contents/MacOS/OpenSCAD
 CONVERT=convert
-SNAPPYVER="v2.0"
+SNAPPYVER="v3.0"
 PARTFILES=$(sort $(wildcard *_parts.scad))
 TARGETS=$(patsubst %.scad,STLs/%.stl,${PARTFILES})
 ROTFILES=$(shell seq -f 'wiki/${SNAPPYVER}-snappy_rot%03g.png' 0 10 359.99)

README.md

@@ -1,6 +1,6 @@
-![Snappy Full Rendering](https://github.com/revarbat/snappy-reprap/wiki/v2.0-snappy_small.png)
+![Snappy Full Rendering](https://github.com/revarbat/snappy-reprap/wiki/v3.0-snappy_small.png)
 
-Snappy-Reprap 2
+Snappy-Reprap 3
 ===============
 
 A parametric design for a cheap self-replicating 3D printer (reprap) that snaps together to minimize screws and non-printed parts.
@@ -10,9 +10,9 @@ Important Links:
 What                 | URL
 -------------------- | -------------------------------------------------------
 GitHub Repository    | https://github.com/revarbat/snappy-reprap
-Project Wiki         | https://github.com/revarbat/snappy-reprap/wiki/v2.0-Home
-Bill of Materials    | https://github.com/revarbat/snappy-reprap/wiki/v2.0-BOM
-How to Assemble      | https://github.com/revarbat/snappy-reprap/wiki/v2.0-Assembly
+Project Wiki         | https://github.com/revarbat/snappy-reprap/wiki/v3.0-Home
+Bill of Materials    | https://github.com/revarbat/snappy-reprap/wiki/v3.0-BOM
+How to Assemble      | https://github.com/revarbat/snappy-reprap/wiki/v3.0-Assembly
 RepRap.org Wiki Page | http://reprap.org/wiki/Snappy
 Dev Forum            | https://groups.google.com/forum/#!forum/snappy-reprap-dev
 

STLs/ramps_mount_parts.stl

@@ -7429,13 +7429,13 @@ solid Model
   facet normal 0 0 0
     outer loop
       vertex -52.275 5 5
-      vertex -4.275 5 5
+      vertex -11.193 5 5
       vertex -44.275 5 5
     endloop
   endfacet
   facet normal 0 0 0
     outer loop
-      vertex -44.275 5 5
+      vertex -52.275 5 5
       vertex -4.275 5 5
       vertex -11.193 5 5
     endloop
@@ -7717,6 +7717,13 @@ solid Model
     outer loop
       vertex -39.275 60 5
       vertex -19.275 60 5
+      vertex -4.275 60 5
+    endloop
+  endfacet
+  facet normal 0 0 0
+    outer loop
+      vertex -39.275 60 5
+      vertex -4.275 60 5
       vertex 30 60 5
     endloop
   endfacet
@@ -7727,13 +7734,6 @@ solid Model
       vertex 54.275 60 5
     endloop
   endfacet
-  facet normal 0 0 0
-    outer loop
-      vertex -19.275 60 5
-      vertex -4.275 60 5
-      vertex 30 60 5
-    endloop
-  endfacet
   facet normal 0 0 0
     outer loop
       vertex -4.275 60 5

bridge_segment_parts.scad

@@ -9,7 +9,7 @@ $fs=2;
 module bridge_segment(explode=0, connectby="")
 {
 	side_joiner_len = 2;
-	l = rail_length - 2 * printer_slop;
+	l = rail_length / cos(bridge_arch_angle) - 2 * printer_slop;
 	spacing = z_joiner_spacing;
 	wall_h = rail_height/2;
 
@@ -34,19 +34,17 @@ module bridge_segment(explode=0, connectby="")
 								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;
+							// Walls
 							xspread(spacing) {
 								up(wall_h/2) {
 									difference() {
 										union() {
 											if (wall_style == "crossbeams")
-												sparse_strut(h=wall_h, l=l-12.1, thick=2.0*lifter_tooth_depth, strut=platform_thick);
+												sparse_strut(h=wall_h, l=l-12.1, thick=rail_thick, strut=platform_thick);
 											if (wall_style == "thinwall")
-												thinning_wall(h=wall_h, l=l-12.1, thick=2.0*lifter_tooth_depth, strut=platform_thick);
+												thinning_wall(h=wall_h, l=l-12.1, thick=rail_thick, strut=platform_thick);
 											if (wall_style == "corrugated") {
-												corrugated_wall(h=wall_h, l=l-12.1, thick=2.0*lifter_tooth_depth, strut=platform_thick);
+												corrugated_wall(h=wall_h, l=l-12.1, thick=rail_thick, strut=platform_thick);
 
 												// Side wiring access hole frame
 												down(wall_h-10/2-rail_thick) {
@@ -69,21 +67,9 @@ module bridge_segment(explode=0, connectby="")
 								}
 							}
 
-							// Wide end cross support
-							up(rail_height/2) {
-								back(l/2-joiner_width/2) {
-									difference() {
-										zrot(90) thinning_wall(l=rail_spacing+2*joiner_width-0.1, thick=joiner_width, h=rail_height, strut=platform_thick);
-										down(rail_height/2-rail_thick-10/2-0.05) {
-											cube(size=[16, 11, 10], center=true);
-										}
-									}
-								}
-							}
-
-							// Center cross support
+							// Cross supports
 							up(wall_h/2) {
-								fwd((l-2*5.5-5)/2) {
+								yspread(l/2-joiner_width, n=3) {
 									difference() {
 										cube(size=[spacing-0.1, 4, wall_h], center=true);
 										down(wall_h/2-rail_thick-10/2-0.05) cube(size=[16, 11, 10], center=true);
@@ -91,21 +77,13 @@ module bridge_segment(explode=0, connectby="")
 								}
 							}
 
-							// Thin end cross support
-							up(wall_h/2) {
-								difference() {
-									cube(size=[spacing-0.1, 4, wall_h], center=true);
-									down(wall_h/2-rail_thick-10/2-0.05) cube(size=[16, 11, 10], center=true);
-								}
-							}
-
 							// Triangle Bracing
 							up(rail_height/2-0.05) {
 								xspread(spacing) {
 									yflip_copy() {
 										back(l/2-6) {
 											front_half() {
-												trapezoid([2*lifter_tooth_depth, rail_height], [2*lifter_tooth_depth, 0.1], h=rail_height/2, center=false);
+												trapezoid([rail_thick, rail_height], [rail_thick, 0.1], h=rail_height/2, center=false);
 											}
 										}
 									}
@@ -115,21 +93,19 @@ module bridge_segment(explode=0, connectby="")
 
 						// 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(rail_spacing+joiner_width) yrot(180) joiner_clear(h=rail_height, w=joiner_width, clearance=1, a=joiner_angle);
+							joiner_quad_clear(xspacing=spacing, yspacing=l-0.05, h=rail_height, w=joiner_width, clearance=1, a=joiner_angle);
 						}
 					}
 
 					// 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(rail_spacing+joiner_width) yrot(180) joiner(h=rail_height, w=joiner_width, l=10, a=joiner_angle);
+						joiner_quad(xspacing=spacing, yspacing=l, h=rail_height, w=joiner_width, l=10, a=joiner_angle);
 					}
 				}
 
 				// Clear space for Side half joiners
 				up(rail_height/2/2) {
-					fwd((l-2*joiner_width-1-0.05)/2) {
+					yspread(l-2*joiner_width-2-0.05) {
 						zring(r=spacing/2+joiner_width/2+side_joiner_len+0.05, n=2) {
 							zrot(-90) {
 								half_joiner_clear(h=rail_height/2, w=joiner_width, a=joiner_angle, clearance=0);
@@ -140,7 +116,7 @@ module bridge_segment(explode=0, connectby="")
 			}
 			// Side half joiners
 			up(rail_height/2/2) {
-				fwd((l-2*joiner_width-1-0.05)/2) {
+				yspread(l-2*joiner_width-2-0.04) {
 					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]]) {

config.scad

@@ -12,7 +12,7 @@ platform_width  = 150.0;  // mm
 platform_height =  40.0;  // mm
 platform_thick  =   5.0;  // mm
 
-rail_length     = 136.0;  // mm  Must be a multiple of lifter_screw_pitch
+rail_length     = 136.0;  // mm  Should match lifter_rod_length
 rail_height     =  50.0;  // mm
 rail_thick      =   5.0;  // mm
 
@@ -34,10 +34,12 @@ motor_shaft_size    =  5;    // mm diameter of NEMA17 motor shaft.
 motor_shaft_length  = 20;    // mm length of exposed NEMA17 motor shaft.
 motor_shaft_flatted = true;  // Is motor shaft keyed? (RECOMMENDED)
 
-lifter_screw_diam   = 60.0; // 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
+lifter_rod_diam     =  25; // mm
+lifter_rod_pitch    =   8; // mm lift per revolution
+lifter_rod_length   = 136; // mm. Must be a multiple of lifter_rod_pitch
+lifter_rod_angle    =  50; // degrees tooth face angle
+lifter_tang_length  =  12; // mm
+lifter_tang_width   =   5; // mm
 
 adjust_screw_diam   =  8.0; // mm
 adjust_screw_pitch  =  3.0; // mm
@@ -142,9 +144,9 @@ 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 = rail_height + groove_height - rack_height/2 - 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;
+lifter_tooth_depth = lifter_rod_pitch / 3.2;
+z_joiner_spacing = lifter_rod_diam + 20 + joiner_width;
+z_base_height = platform_z + rail_offset - groove_height/2;
 adjust_thread_depth = adjust_screw_pitch/3.2;
 drive_gear_diam = (gear_teeth+2)*rack_tooth_size/pi;
 

docs/assembly/RAMPS_Wiring_For_Snappy.svg

@@ -619,7 +619,7 @@
          id="tspan6049"
          x="50.9739"
          y="91.169952"
-         style="font-size:9.52499962px;line-height:1.25;stroke-width:0.26458332">RAMPS 1.4 Wiring for Snappy RepRap v2.0</tspan></text>
+         style="font-size:9.52499962px;line-height:1.25;stroke-width:0.26458332">RAMPS 1.4 Wiring for Snappy RepRap v3.0</tspan></text>
     <g
        id="g6068">
       <path

docs/assembly/index.html

@@ -158,6 +158,30 @@ UL {
 </li>
 </ul>
 </li>
+<li class="section"><h2>Lifter Assembly</h2>
+<ul>
+<li class="step"><h3>Step 1</h3>
+<div class="desc">Press fit a nut into slot on the bottom of lifter coupler.  Press into slot until it reaches the bottom.</div>
+<table><tr><td class="befor"><img src="lifter_assembly_1_before.png"></td><td class="arrow"><img src="arrow.png"></td><td class="after"><img src="lifter_assembly_1_after.png"></td></tr></table>
+</li>
+<li class="step"><h3>Step 2</h3>
+<div class="desc">Thread a 3mm x 12mm screw just barely through the nut in the screwhole.</div>
+<table><tr><td class="befor"><img src="lifter_assembly_2_before.png"></td><td class="arrow"><img src="arrow.png"></td><td class="after"><img src="lifter_assembly_2_after.png"></td></tr></table>
+</li>
+<li class="step"><h3>Step 3</h3>
+<div class="desc">Press fit the lifter rod fully onto the top of the coupler.  If it's loose at all, superglue them carefully together.</div>
+<table><tr><td class="befor"><img src="lifter_assembly_3_before.png"></td><td class="arrow"><img src="arrow.png"></td><td class="after"><img src="lifter_assembly_3_after.png"></td></tr></table>
+</li>
+<li class="step"><h3>Step 4</h3>
+<div class="desc">Press fit another lifter rod fully onto the top of the lifter assembly.  Superglue it carefully if it is at all loose.</div>
+<table><tr><td class="befor"><img src="lifter_assembly_4_before.png"></td><td class="arrow"><img src="arrow.png"></td><td class="after"><img src="lifter_assembly_4_after.png"></td></tr></table>
+</li>
+<li class="step"><h3>Step 5</h3>
+<div class="desc">Press fit the lifter rod assembly onto the stepper motor shaft, making sure the set screw is on the flatted side of the shaft.  Tighten the set screw firmly.  Apply mineral oil to the screw rod threads for lubrication.</div>
+<table><tr><td class="befor"><img src="lifter_assembly_5_before.png"></td><td class="arrow"><img src="arrow.png"></td><td class="after"><img src="lifter_assembly_5_after.png"></td></tr></table>
+</li>
+</ul>
+</li>
 <li class="section"><h2>Z Tower Assembly</h2>
 <ul>
 <li class="step"><h3>Step 1</h3>
@@ -177,9 +201,13 @@ UL {
 <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>
+<div class="desc">Slide the lifter assembly (motor and lifter rods) into the motor mount on the Z base segment of the topwer assembly.</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>
+<li class="step"><h3>Step 6</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_6_before.png"></td><td class="arrow"><img src="arrow.png"></td><td class="after"><img src="z_tower_assembly_6_after.png"></td></tr></table>
+</li>
 </ul>
 </li>
 <li class="section"><h2>Extruder Assembly</h2>
@@ -244,14 +272,6 @@ UL {
 <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>
-<div class="desc">Press fit the lifter screw onto the stepper motor shaft, making sure the flatted side matches that on the lifter screw shaft hole.  (The hole on the lifter screw rim is aligned with the flatted side.)  Apply mineral oil to the screw threads for lubrication.</div>
-<table><tr><td class="befor"><img src="bridge_assembly_4_before.png"></td><td class="arrow"><img src="arrow.png"></td><td class="after"><img src="bridge_assembly_4_after.png"></td></tr></table>
-</li>
-<li class="step"><h3>Step 5</h3>
-<div class="desc">Insert the Z stepper motors into the motor mount cages on the Z-sleds at both ends of the bridge.  Route the wiring to the left-side front wiring access hole with the rest of the extruder wiring.</div>
-<table><tr><td class="befor"><img src="bridge_assembly_5_before.png"></td><td class="arrow"><img src="arrow.png"></td><td class="after"><img src="bridge_assembly_5_after.png"></td></tr></table>
-</li>
 </ul>
 </li>
 <li class="section"><h2>Top Brace Assembly</h2>